What’s so special about that, you ask? Isn’t that what rain gear is supposed to do? But what if I told you I’ve worn this set for over five years of demanding dual-sport and adventure riding across several continents, through unforgiving conditions that chewed up and spat out lesser gear? Stick around, and I’ll show you why the Traverse might be the last waterproof shell you ever need to buy.

Klim Traverse Jacket

Klim Traverse Jacket and Pants offer rugged, lightweight protection built for off-road adventure with all-weather performance.

Pros:

• Gore-Tex waterproofing keeps you dry in all conditions
• Durable 500D Cordura reinforcements for high-impact areas
• Lightweight design enhances mobility and reduces fatigue

Cons:

• Back protector for jacket sold separately

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My Journey to Finding Reliable Wet Weather Gear

I can’t even begin to count how many sets of rain gear I’ve owned in more than half a century of riding. But they all had one thing in common: they never lasted long. Sooner or later, they invariably failed to keep me dry. Whether it was poor design, shoddy workmanship, material failure, prematurely worn out, or damaged by (ab)use, it was just a matter of time before that dreaded feeling of cold water trickling down my crotch, back, leg, or elbow pit would set in. 

If you have ever experienced this all-too-familiar miserable feeling, you know how distracting, irritating, and downright frustrating it is. The treacherous trickle of those first glacial droplets is only the beginning of an insidious ingress of cold water bound to make your ride a miserable ordeal. When the floodgates open on a chilly day, leaking rain gear will turn you into a shivering blob of jelly in no time, making you wish you’d taken up collecting postage stamps as a hobby instead of motorcycling.

Typical rain gear for off-road riding almost always consists of a thin, waterproof polyester or polyamide (nylon) shell. Riding on rough terrain requires standing on the pegs, demanding much greater physical exertion than cruising on the road. To help abate fatigue, seasoned dirt riders avoid donning heavy, bulky shells like the yellow PVC ‘oilskin’ rain gear sailors and construction workers wear, even though it’s much more durable than polyester or nylon. 

Living by the motto of “less (weight) is more (fun)”, off-road riders favor rain gear made of a thin plastic layer, keeping the shell lightweight, flexible, and compact. Experienced enduro riders know why these interrelated criteria matter. But if you’re new to enduro/dual-sport riding and not sure what to buy, consider that lightweight, flexible rain gear doesn’t weigh you down, aiding mobility and agility and reducing fatigue. Compactness or packability matters too, since rain gear is stowed when it’s not raining or cold. However, its downside is that a flimsy shell lacks strength and abrasion resistance. Hence, it shreds when hooking up on branches or hitting the ground when you suddenly feel the urge to collect soil samples.

I’ve tried it all: dedicated rain suits that felt like wearing a plastic ‘rapid weight loss’ sauna suit, expensive laminated jackets that were too bulky or eventually wetted out, cheap throwaway ponchos that shredded in the wind – you name it. I was searching for that perfect balance, that trifecta of comfort, durability, and functionality that would help to keep enduro/dual-sport riding FUN in inclement weather. Alas, the gear gods never answered my prayers.

Traversing 15 Years

Until the Klim Traverse entered the stage fifteen years ago. It first appeared on my radar soon after its launch in 2010. Although I tend to be a ‘first adopter’ of game-changing gear, I declined the offer as it didn’t tick off all the ‘criteria’ boxes on my wish list. I was already a Klim user long before the Idaho-based brand became a household name in the motorcycle gear industry. I bought my first two Klim off-road pants in 2004 after a friend in the trade introduced me to this brand I’d never heard of. Klim was only known for its snowmobile gear, and their 2004 off-road collection was the brand’s first foray into motorcycle apparel.

I considered buying the redesigned, second generation of the Klim Traverse when it was launched in 2016. But again, I didn’t pull the trigger, as it still didn’t fit all my requirements. The tough 680D Cordura overlays on the high-wear impact areas (elbows, shoulders, knees, and seat of the pants) made the Traverse very resistant to cuts, scuffs, and abrasion. However, that ruggedness made it heavier, stiffer, bulkier, and less packable, which was a deal breaker.

I was holding out for the Holy Grail: a lightweight, waterproof combo for enduro and dual-sport riding that was durable and flexible but still relatively thin and compact enough to be packable. Weight and packability are important as I carry my rain gear in my backpack or strapped onto the bike. The rugged 2016 Traverse catered more to ADV riders, for whom abrasion-resistance matters more in case of a high-speed get-off.

But then, in 2020, the gear gods took pity on me and answered my prayers when Klim launched the redesigned third-generation Traverse, repositioning it more towards the off-road end of the spectrum. This was a welcome move, although some ADV riders who owned the previous two generations lamented the reduced ventilation and abrasion resistance. But that criticism was unwarranted, as Klim offers other combos (e.g., the Klim Badlands Pro and Carlsbad) that cater to the ADV segment.

When Klim returned to the drawing board for the third generation, they revised the Traverse to realign it with its core mission, as it was always intended for off-road use. Engineered specifically for the unpredictable weather encountered during full seasons of dual-sport riding, Klim focused on boosting comfort and cutting bulk. 

Thinner, lighter, and more flexible, the third-generation Traverse is the ideal waterproof kit for dual-sport and hard-core enduro riders who ride in all seasons. With its “Guaranteed to Keep You Dry” Gore-Tex Performance Shell, the Traverse offers serious foul weather protection while being much tougher than basic rain jackets and pants. 

With reduced vents and substituting 500D for the 680D Cordura overlays, the current Traverse’s supple lightweight chassis is less bulky and cumbersome than the previous generation. Its minimalistic shell delivers on the promise of fully protecting the rider against inclement weather, season after season, without the weight and bulk of a full-fledged 4-season ADV suit.

Let me tell you how it held up to that promise over years of abuse.

Putting the Traverse Through Its Paces: Real-World Stories

This gear hasn’t sat in a closet. Over the years, it’s seen deserts, mountains, jungles, and everything in between.

TET France Downpour Nightmare: Riding solo on the Trans Euro Trail across the windswept plains of northern France on a cold early spring day, the low cloud deck grew menacingly dark, and then the sky just opened up. Not rain, but a torrential, freezing downpour mixed with sleet. Slipping and sliding through the greasy mud of the tracks deeply rutted by farming tractors, I grew weary of the ice-cold rain that wouldn’t relent. When I crossed from the Nord-Pas-de-Calais region into Picardy, I had enough and veered onto the paved roads, looking for shelter. But I dread to think what a potentially life-threatening, hypothermic ordeal it might’ve been without proper rain gear. Fortunately, I stayed bone dry inside the Traverse. The Gore-Tex just worked, shedding water relentlessly. The only moisture inside the Traverse was my sweat from wrestling the bike through the mud. But that didn’t chill my body, as the Klim Teton Merino Wool Long-Sleeve Shirt and Pants wicked away the sweat, keeping me dry and warm. That day sold me on the shell and layering concept.

Moab Muddy Mayhem: Hitting some slick red rock trails after a rainstorm meant lots of skidding, slipping, and sliding, resulting in frequent get-offs. Picking up a bike laden with camping gear while wearing boots that fail to find traction on the red goo gets old quickly. The 500D Cordura overlays on the knees, elbows, and seat took a beating but showed minimal wear. Hosing off the slimy muck at the car wash in town was surprisingly easy, and it was ready to go the next day. Lesser gear would have been shredded or stained permanently.

Big Temperature Swings on the ACT in the Spanish Pyrenees: Think about those fall rides where you start off freezing, work up a sweat in the afternoon sun, and then freeze again as evening sets in – conditions you might find in mountain regions. Layering up under the Traverse was key for crossing the Pyrenees via the Adventure Country Tracks in late fall. With the vents open (collar, pit zips, front and rear thigh vents), it breathed reasonably well during the warmer parts of the day. When temps dropped, zipping everything up tight and relying on Klim’s technical base and mid-layers kept me comfortably warm. The Traverse shell worked perfectly with the layers; it felt like cheating the weather. When the temperatures plummet, you add mid-layers; when they rise, you simply remove layers and the shell and stow it away.

Torrential Trans-Canada Adventure Trail: It was (too) late in the fall when I rode south along the coast to Vancouver after exploring parts of the Trans Canada Adventure Trail in British Columbia and Alberta for a few weeks. What started as a steady drizzle turned into a deluge when I approached Whistler, which didn’t let up until I reached Vancouver. The Traverse was a true lifesaver that day, as I stayed bone dry riding for hours in absolutely torrential rain. No leaks and no wet-out feeling through the fabric. The cinched collar kept rain from trickling down my neck, and the pant cuffs sealed perfectly over my boots. Although not designed for highway surfing, the Traverse performed its core function flawlessly.

The “Drop Test” in Northern Thailand’s Himalayan Foothills: Lots of spills on the hard-packed jungle tracks in the mountains of northern Thailand. Usually, it’s due to the rear wheel coming around when accelerating out of a corner or the front end washing out, resulting in shoulders, elbows, and hips taking the brunt of the impact. The Traverse shell slid across the slick soil numerous times but never wore through. Scuffed the Cordura a bit? Sure. But no holes or tears, and the armor underneath did its impact protection job. It proved the shell material was tough enough for typical dual-sport spills.

What I Like About the Klim Traverse (After 5 Years)

• Bulletproof Gore-Tex Waterproofing: This is the main event. Klim’s implementation of the Gore-Tex Performance Shell is simply outstanding. It works. Period. The crotch stays dry, the cuffs seal well, and the gusseted fly, adjustable cinched collar, and bottom hem keep water out. The Traverse has been utterly reliable compared to countless other jackets and pants that claimed waterproofness but failed after a season or in sustained rain. “Guaranteed To Keep You Dry®” isn’t just marketing speak here.
• Surprising Durability: For a relatively lightweight shell, it’s tough. The main body fabric holds up well and the strategic placement of the rugged 500D Cordura in high-wear/impact areas (shoulders, elbows, forearms, knees, seat) makes a huge difference. It survived slides, snags on branches, and general trail abuse far better than I expected. It’s a noticeable step up from the typical cheap, flimsy, rain gear. The 500D Cordura overlays endured numerous spills unscathed on treacherous trails in the Pyrenees, the Sierra Nevada, and the Himalayan foothills.
• Effective Ventilation (for a Shell): Let’s be realistic: no waterproof gear breathes like mesh. But for rain gear, the Traverse has generous vents. The jacket sports two waterproof 13-inch/33-cm zippered pit vents and a velcro collar tab retainer, keeping the collar open without letting it flap in the wind. The pant has four waterproof YKK zippered vents on the thighs: two 10-inch/25-cm intake vents and two 6-inch/15-cm exhaust vents. They flow a decent amount of air when moving, significantly extending the comfort range compared to non-vented rain shells. They make dealing with changing temps and exertion levels much more manageable. And when temperatures rise beyond the vents’ cooling capacity, you simply take it off and stow it.
• Great Fit for Active Riding: Klim apparel’s cut is known to be generous. The Traverse shell offers a roomy “active” fit designed to go over body armor and mid-layers without bunching up or limiting movement, whether standing or sitting. Its generous cut offers more articulation in the elbows and knees, even with separate body armor and knee braces. The flexible nylon fabric chassis feels less bulky and cumbersome than laminated adventure suits.
• Relatively Lightweight & Packable: Compared to Klim’s more feature-heavy ADV gear like the Badlands or Carlsbad, the Traverse feels significantly lighter and packs down smaller (though not as small as the typical flimsy ‘sheet’ rain shells). Its minimalist shell makes it great for trips where space and weight are a concern.

What I Don’t Like (The Tradeoffs)

The Included Armor: To avoid creating the wrong impression, there’s nothing wrong with the D3O protective armor in the high-impact zones. If you’re new to dual-sport or ADV riding and don’t have any protective gear yet, you’ll certainly want the impact protection that comes with the Traverse jacket and pants. The soft, flexible, ventilated D3O® LP1 Limb Protectors are inserted in the shoulders, elbows, knees, and hips lining pockets. (LP1 means level 1 impact protection certified to CE safety standard EN1621-1:2012). 

As every dual-sport and enduro rider knows, falling (frequently) is part and parcel of trail riding. To prevent bruises or worse, I would opt for the highest impact protection level, requiring substituting the LP1 pads with the more protective LP2 pads. But the problem is that, when stashed in your backpack or strapped to the bike, the inserted D3O pads (LP1 or LP2) add volume to the Traverse, making it bulkier and unwieldy to pack. 

But that’s not my main gripe. The disadvantage of inserted protection pads is that you’re unprotected when your rain gear is stowed away. Like most enduro/dual-sport riders, I wear a separate ‘stand-alone’ body armor system, which offers better impact protection and maximizes ventilation and breathability. Donning body armor allows the removal of the D3O inserts, keeping the shell light, compact, and packable. Over the years I’ve reinserted the D3O impact pads only a handful of times when riding my Honda NSS 300 Forza scooter on a rainy day. 

Since I don’t need them, I would prefer Klim to make the D3O pads optional, as they do for the Klim Raptor GTX Overshell, allowing for a small price reduction of the Traverse.  

Klim recommends combining the Traverse shell with the Klim Tactical Pro Armored Long-Sleeve Shirt and Tactical Pants. Apart from body armor, I always wear knee braces when riding off-road. 

Alternative: If you want a lightweight rainproof shell with more abrasion resistance, consider the Klim Raptor GTX Overshell Jacket and Pants. The Raptor shell features the ultra-abrasion-resistant SuperFabric on shoulders, elbows, and knees, and thicker, more durable 840D Cordura on the inner knee, boot panels, and seat of the pants. However, these reinforcements make the Raptor GTX Overshell thicker, bulkier, and less compact when packed than a Traverse without the D3O pads. 

The Price Tag: Klim gear isn’t cheap, and the Traverse is no exception. However, the price tag includes the lifetime Gore-Tex “Guaranteed to Keep You Dry” warranty. That’s worth a lot, especially compared to other brand shells. Given its proven multi-year durability and performance, the cost-per-wear becomes much more reasonable than replacing cheaper rain gear multiple times every year. Think of it as an investment that yields annual dividends over many years. The REV’IT! Component H2O and Mosko Moto Rak Pullover are comparable shells at similar price points and functionality. 

Limited Pockets: It has the basics (hand pockets, chest pocket, internal pocket), but fewer than you’d find on a touring or ADV jacket. However, fewer pockets mean fewer seams and zippers, reducing potential failure points for water ingress and keeping the design cleaner and lighter. You can also supplement with a backpack (like the Klim Arsenal Backpack series) or a Mosko Moto tank bag or tail bag if you need to carry more stuff.

Can Still Get Warm: Despite the vents, in slow, technical, high-exertion riding in hot, humid weather, you will sweat. It’s a waterproof membrane, after all. However, it’s still vastly better than wearing a non-vented rain suit in those conditions. You can also just take it off and stow it!

Need-to-Knows & Fun Facts

• Sizing: Generally follows Klim’s typical “American” cut – generous and designed for layering. Check the Klim Size Chart. Tall and short pant sizes are usually available.
• Layering is Crucial: This is a shell, not an insulated suit. Your comfort across different temperatures depends entirely on your base and mid-layers. Plan accordingly.
• Gore-Tex Care: To maintain performance, wash it periodically with a tech wash (like Nikwax Tech Wash) and tumble dry on low/medium heat to reactivate the DWR coating. Don’t use regular detergents or fabric softeners!
• Minimalist Design: The lack of some features (like tons of pockets and vents) is a deliberate choice to keep it light, flexible, compact, and leakproof for its intended dual-sport/off-road use.

How Does it Compare

VS Mosko Moto Rak/Basilisk

Mosko gear is known for extreme toughness and innovative features, often with a different design philosophy, fit, and characteristics. Choose Mosko Basilisk if you prioritize maximum abrasion resistance and unique features; choose Traverse for proven, straightforward Gore-Tex performance and reliability.

Basilisk IR Armored Adventure Motorcycle Jacket

The Basilisk IR Jacket is a minimalist, high-performance shell built for serious off-road adventure.

Pros:

• CE-Level 2 impact protection
• Waterproof yet breathable shell
• Lightweight and easy to pack

Cons:

• Limited availability due to import changes

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 The Mosko Moto Rak Pullover (name derived from Anorak) sells for the same price ($479) as the Traverse Jacket, its Klim equivalent.

The Basilisk IR Jacket is more expensive ( $721) due to its large area of SuperFabric, making it extremely abrasion-resistant.

VS REV’IT! Component H2O

The REV’IT! Component 2 H2O offers a slimmer, more European fit and uses its proprietary Hydratex waterproofing. Compare long-term waterproof durability reviews carefully against Gore-Tex’s track record.

REV'IT! Component 2 H2O Jacket

The REV'IT! Component 2 H2O Jacket is a lightweight, waterproof shell built for serious off-road riders who demand comfort and protection.

Pros:

• Waterproof Hydratex 3L membrane keeps you dry in harsh conditions
• Stretch ripstop fabric offers flexibility and comfort on rugged trails
• SEESMART CE-level 1 armor provides lightweight impact protection

Cons:

• Runs small and may require sizing up for proper fit

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VS Klim Carlsbad

The Klim Carlsbad is the Traverse’s more expensive ADV sibling, featuring integrated D3O armor, more pockets, and slightly different venting/materials. Choose Carlsbad if you want an all-in-one armored Gore-Tex suit; choose Traverse if you prefer a lighter, simpler, more compact shell.

Klim Carlsbad Jacket and Pants

The Klim Carlsbad Jacket and Pants are built for adventure riders seeking rugged, weather-resistant gear with excellent mobility and protection.

Pros:

• Gore-Tex performance shell offers guaranteed waterproofing
• Abrasion-resistant fabrics and CE Level 2 armor enhance durability and safety
• Multiple vents provide adjustable airflow for varying climates

Cons:

• Premium pricing may be out of range for budget-conscious riders

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VS Klim Raptor GTX Jacket

The Klim Raptor GTX Overshell Jacket and Pants are a step up from its lighter sibling, the Traverse. Also part of Klim’s off-road catalog, the Raptor GTX is a more rugged rainproof shell, upgraded with SuperFabric reinforcements on impact zones to make it more abrasion-resistant. 

Klim Raptor GTX Overshell Jacket and Pants

The Klim Raptor GTX Overshell Jacket and Pants offer elite weatherproofing for serious adventure riders.

Pros:

• Gore-Tex Pro shell for waterproofing
• Superfabric for abrasion resistance
• Fits over armored layers

Cons:

• No built-in insulation

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The Final Verdict: Is the Klim Traverse GTX Worth It?

After five years of intensive (ab)use, covering thousands of miles across tricky terrain and in unforgiving weather, my Klim Traverse suit is still intact, waterproof, and with all zippers fully functional. It looks surprisingly good given the harsh treatment my riding (mis)adventures have inflicted upon it. Its durability has exceeded my expectations. If you’re looking for rain gear whereby reliable waterproofing, flexibility, packability, and durability are paramount, don’t look any further. It’s not flashy and doesn’t have every bell and whistle, but it does its core job – keeping you dry and protected from the elements – exceptionally well, year after year.

This gear is PERFECT for:

• Serious enduro/dual-sport riders tackling tricky trails in inclement weather.
• Riders who prioritize bombproof waterproofing and long-term durability.
• Those who prefer to customize their protective armor system separately.
• Multi-season riders who understand and utilize layering systems.

This gear is NOT the best fit for:

• Primarily street/ADV riders who need a higher level of abrasion protection.
• Strictly budget-conscious buyers (though consider the long-term value).
• Touring/Street/ADV riders who need more built-in storage (internal and external pockets) and creature comforts.
• Riders in hot climates who rarely see rain (for whom mesh is better).

Is it worth the investment? Absolutely! At least if your riding demands gear that won’t let you down when the weather turns nasty. It might not make you ride like a champ, but when that mother of all rainstorm hits, you’ll be glad you’re wearing it. It just works.

Klim Traverse GTX Jacket & Pant Key Features

Jacket:

• Shell/Construction: GORE-TEX PERFORMANCE SHELL (Guaranteed To Keep You Dry®), 500D Cordura® overlays on shoulders/elbows/forearms, 3M™ Scotchlite™ carbon black reflective material.
• Armor System: Removable vented D3O® Level 1 armor in shoulder and (adjustable) elbow pockets. Pocket for optional back protector (compatible with D3O® Level 1 & 2 – back protector sold separately).
• Ventilation: Two 13-inch/33-cm-long armpit vents (with mesh and dual waterproof YKK zippers), velcro collar tab retainer to keep the collar open for ventilation and prevent it from flapping in the wind.
• Storage: 2 large waterproof YKK zippered hand pockets, 1 large waterproof zippered chest pocket, 1 large internal zippered chest pocket with headphone port.
• Fit/Comfort: Breathable mesh lining. The chassis is longer in the back for comfort and mobility, articulated fit, adjustable collar with elastic cinch pull cord and velcro tab retainer for ventilation, bottom hem cinch cord, and adjustable velcro cuffs.

Pants:

• Shell/Construction: GORE-TEX PERFORMANCE SHELL (Guaranteed To Keep You Dry®), 500D Cordura® overlays on knees/seat/lower leg, heat-resistant leather panels on inner knees. 3M™ Scotchlite™ carbon black reflective material.
• Armor System: Removable vented D3O® Level 1 hip and (adjustable) knee armor (upgradable to Level 2 – sold separately).
• Ventilation: 2 frontal intake vents and 2 rear exhaust vents on the thighs, with mesh and waterproof YKK zippers.
• Storage: 1 waterproof YKK zippered large cargo pocket.
• Fit/Comfort: Breathable mesh lining, adjustable waist velcro cinch straps, articulated seat and leg profile for rider position, over-the-boot adjustable cuff design with 3 velcro strips, waterproof zippered gusset fly, and double snap button closure.

You can find the Klim Traverse Klim Traverse GTX Jacket and Pants here.

Klim Traverse Jacket

Klim Traverse Jacket and Pants offer rugged, lightweight protection built for off-road adventure with all-weather performance.

Pros:

• Gore-Tex waterproofing keeps you dry in all conditions
• Durable 500D Cordura reinforcements for high-impact areas
• Lightweight design enhances mobility and reduces fatigue

Cons:

• Back protector for jacket sold separately

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The post Klim Traverse GTX 5-Year Review: Still Waterproof? first appeared on It's Better On The Road.

But if you live and ride in the real world where it does get cold, the kind of cold that freezes your nuts off (t*ts for the ladies), you’ll need a different outfit. Add into the equation the windchill factor, which rises exponentially with the velocity indicated on your speedometer, and you’ll need to jazz up your riding combo with layers of warm clothing, including battery-powered heated layers.

But how often do you ride naked, only wearing boxers and a helmet when it’s hot? Rarely, right? Layering with vented or mesh gear shields your skin from the sun, keeping you cool and preventing the risk of skin cancer. 

You may even need a cooling vest to control your body temperature when it’s stifling hot. Especially enduro/dual-sport/ADV riders are at risk of overheating when ‘technical’ off-road riding on gnarly terrain where physical exertion is high and speeds and hence airflow is low.

When it’s hot, you’re bound to see a squid (Stupidly Quick, Underdressed, and Imminently Dead) riding in shorts and a T-shirt, unintentionally volunteering to become an organ donor. Or at least involuntarily posing for social media photos of horrendous injuries after being tossed off the bike.

If you agree that scars and skin grafts look unsightly and fractured bones and crippled joints are rather inconvenient, your layering should include some decent—read: CE-certified—abrasion and impact protection. 

The Gear section of this website contains articles and reviews discussing various styles of jackets, armor, and layers. In this article, I’ll take you on a tour of technical layers, what they entail, the ins and outs of the various materials, technicalities, and specs, and the resulting performance aspects. This will allow you to make an informed decision based on your requirements, preferences, and budget. 

The first part of this article introduces you to The Art of Layering. If, after reading part one, you’re still thirsty for knowledge, I invite you to continue reading. The second part introduces you to The Science of Layering.

Given the importance of the topic for your safety, comfort, and enjoyment of what is most likely your passion, reading this informative piece will be time well spent. Grab your preferred beverage, lean back in a comfy chair, and follow along.

For the best base layers in the biz, check out Klim. I’ve reviewed a whole set here. 

Boxers	Pants	Shirt
Klim Teton Merino Shorts	KLIM Teton Merino Wool Pants	KLIM Teton Merino Wool LS Shirt
Primary Rating: 5.0	Primary Rating: 5.0	Primary Rating: 5.0
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Boxers

Klim Teton Merino Shorts

Primary Rating:

5.0

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Pants

KLIM Teton Merino Wool Pants

Primary Rating:

5.0

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Shirt

KLIM Teton Merino Wool LS Shirt

Primary Rating:

5.0

Check Price on Amazon

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Part I: The Art of Layering

Understanding Technical Layers for Safety and Comfort

Riding a motorcycle isn’t just about hitting the open road and throwing all caution to the wind; on the contrary, it’s about being prepared for whatever the elements put on your path. Whether you’re tackling twisty mountain passes in the biting cold or riding through the sweltering summer heat, having the right gear can mean the difference between an enjoyable ride and a miserable one—or worse, an unsafe one. 

Motorcycle gear is typically divided into three technical layers: base layers, mid-layers, and outer shells. Each layer has a specific function:

• Impact absorption
• Abrasion protection
• Thermal insulation
• Body temperature regulation
• Moisture-wicking/perspiration management
• Breathability
• Ventilation
• Cooling

When combined properly, the three layers work together synergistically, optimizing the performance of the layers in providing both safety and comfort in any weather condition.

Base Layers: Moisture-Wicking and Temperature Regulation

The base layer sits directly against your skin and serves two primary purposes: moisture management and temperature regulation. When dressed in motorcycle gear, perspiration is inevitable, especially in hot weather or due to physical exertion during enduro/dual-sport/ADV-riding.

A good technical base layer, typically made from synthetic performance fabrics or merino wool, is designed to wick sweat away from your body. This keeps you dry, which is crucial in both hot and cold environments. 

In the summer, a moisture-wicking base layer helps to keep you cool by facilitating evaporation. In colder conditions, staying dry is equally important because wet clothing will rapidly suck heat away from your body, leaving you cold and uncomfortable. It can lead to hypothermia, which can turn lethal in extreme cases. (Hypothermia is a condition that occurs when your core body temperature drops below 95 °F or 35 °C).

Best Features of Base Layers:

• Moisture-wicking fabrics like polyester, nylon, or merino wool
• Quick-drying properties
• Lightweight
• Breathable
• Soft and cozy
• Often snug or form-fitting to reduce bulk under other layers

In colder conditions, thermal base layers (often referred to as “long johns”, “leggings” or “thermals”) help to retain heat while still wicking moisture, preventing you from getting clammy. So, your base layer isn’t just about keeping you dry—it’s the foundation for your entire body temperature control system.

Mid-Layers: Insulation for Warmth

The mid-layer’s job is all about insulation and trapping the warmth your body generates. Think of it as your personal vestimentary climate control system. 

When riding in cold weather, you need a mid-layer that provides sufficient warmth without restricting movement. Materials like fleece, down, or synthetic insulations like Primaloft or Thinsulate are commonly used in mid-layers. These materials work by trapping warm air close to your body, creating a barrier against the cold. 

A mid-layer can be anything from a fleece shirt to a Merino wool pullover or goosedown puffer jacket, or a combination thereof, depending on how cold it is. The beauty of the mid-layer is its adaptability, making it the most versatile layer of your layering system. On warmer days, you might skip it entirely, but in colder temperatures, it can be the difference between an enjoyable ride and freezing your t*ts off.

Click on the following links if you want to know more about Merino Wool, Goose-Down Puffer Jackets, and Synthetic Insulation.

Best Features of Mid-Layers:

• Versatility
• Thermal insulation (fleece, wool, down, synthetic insulation)
• Lightweight 
• Compressible (important for storing when not in use)
• Breathability to allow perspiration to evaporate
• Can be used on its own (as casual clothing)

In colder conditions, you might choose a natural down or synthetic down jacket for its excellent warmth-to-weight ratio. In wet conditions, a synthetic mid-layer performs better since it retains its insulating properties even when damp, whereas down tends to lose its effectiveness when wet.

Outer Shell: Protection from Impact, Abrasion, and Weather

The outer layer, or shell, is your main line of defense against both the elements and the hazards of the road. Its primary functions are impact absorption and abrasion protection, as well as shielding you from inclement weather conditions. 

Motorcycle jackets and pants often come with integrated armor to protect key areas like your elbows, shoulders, knees, and back in case of a crash.

Outer shells are typically made from durable materials like leather or high-performance textiles that offer varying degrees of abrasion resistance, weather protection, breathability, and ventilation. 

Typical high-performance fabrics used in motorcycle gear are:

• Vectran (a brand name for a high-performance fabric made from an aromatic polyester multifilament spun from a liquid crystal polymer in a melt extrusion process. This process orients the molecules along the fiber axis, resulting in a high-tenacity fiber that is five times stronger than steel)
• SuperFabric (a brand name for an extremely abrasion-resistant, hi-tech fabric covered with a pattern of tiny, hard, ceramic guard plates on a nylon or polyester substrate).
• Cordura (a brand name for a durable synthetic fabric woven from high-tenacity air-jet textured nylon 6,6 filament yarns. Its high-tensile strength makes it resistant to abrasion, tears, and scuffs) 
• Kevlar (a brand name for a type of lightweight, heat-resistant, high-tensile-strength aramid polymer fiber that is five times stronger than steel)

For adventure touring and off-road riding, many riders prefer textile gear, as it’s generally more versatile in different weather conditions. 

Leather, while offering superior abrasion protection, is less comfortable in hot weather, even if it’s perforated or combined with vents for airflow. Leather is also not rainproof and takes a long time to dry.

Best Features of Outer Shells:

• Abrasion-resistant materials (leather or textile)
• CE-certified armor for impact protection
• Ventilation zippers or mesh panels for airflow on hot days
• Waterproof and windproof membranes (Gore-Tex or similar) to keep rain out
• Adjustable fit to accommodate layering

The outer shell plays a critical role in maintaining breathability while protecting you from the elements. Jackets and pants with zippered vents or mesh panels allow you to open up airflow on warmer days, while waterproof membranes help you stay dry when the skies open up.

Combining Layers for Optimal Comfort and Safety

To create the perfect riding system, the key is combining these layers in a way that suits the weather conditions. On a chilly morning ride, you might start with a moisture-wicking base layer to manage sweat, a fleece or insulated mid-layer for warmth, and then top it off with an abrasion-resistant jacket for protection against the wind and cold. As the day warms up, you can remove the mid-layer and open the vents in your outer shell to let air in, without sacrificing protection or safety.

For summer riding, the base layer remains essential for moisture-wicking, but your mid-layer might be unnecessary. A well-ventilated outer shell with armor and abrasion protection will keep you cool while still shielding you from the sun, wind, and any potential crashes.

In wet weather, you may rely more heavily on your outer shell’s waterproof capabilities, while a base layer continues to wick moisture away from your skin. A lightweight, water-resistant mid-layer can help to maintain body heat in cold, wet conditions.

Conclusion of Part I: The Power of Layering

By properly layering your gear, you create a flexible system that can adapt to any weather or riding condition. Each layer serves a specific function—whether it’s keeping you dry, warm, or protected from impacts—making sure that you stay comfortable and safe no matter what the road or trail throws at you. With a solid understanding of how these layers work together, you’ll be able to confidently tackle long-distance rides, unpredictable weather, and any adventure on two wheels. After all, motorcycling is about freedom, and the right gear makes that freedom more enjoyable and, most importantly, safer.

Now that you’re introduced to the Art of Layering, do you also want to understand the Science of Layering? If so, then keep on reading. 

Part II: The Science of Layering

Do You Need Thermal Base and Mid-Layers?

You don’t need thermal layers if you only ride in the tropical heat. But if you live in a colder climate or plan a summer trip in the Alaska Range or Colorado Rockies, you’ll need some serious gear. 

“There’s no such thing as bad weather, only unsuitable clothing.”

If you’re familiar with alpine microclimates, you know how fickle the weather can be at altitude. One moment you’re riding up a south-facing slope under sunny blue skies, but the minute you cross over the pass, the rain or fog on the north face is so dense you can barely see your front wheel, not to mention the drastic drop in temperature. 

Donning protective motorcycle gear is vital in any scenario, but you can’t rely on the weather forecast to dictate your attire at high altitudes. Mountain ranges create an unpredictable microclimate, requiring you to come prepared with all-weather, four-season riding gear. Riding in the desert is equally challenging, as the temperatures can drop dramatically at night.

Like everything you buy, quality comes at a price. It’s no different with top-quality technical riding gear. But if you look at the purchase as an investment instead of a cost, it quickly makes sense. When you’re on that once-in-a-lifetime Himalayas tour, snug as a bug in your cozy Klim Maverick Down Jacket, the last thing you’ll be thinking is, “I wonder if I could have saved $100 by going for the Walmart jacket instead.” But if you’re freezing due to subpar insulation, you’ll most definitely wish you’d spent $100 more. 

An investment pays dividends, and technical riding gear does too: it yields an ROI (return on investment) by keeping you warm, dry, and safe.

Over the years, my experience taught me that top-quality gear is worth more than its price tag. If you’ve ever been thoroughly soaked, chilled to the bone, and had your shriveled cojones resemble frozen popsicles after riding for hours in the rain, you’ll never forget the utterly miserable experience. 

Having ample experience with both crappy attire and top-notch technical riding gear, I agree with Alfred Wainwright, the British author of walking guidebooks, who commented: “There’s no such thing as bad weather, only unsuitable clothing”. This credo may well underlie the design philosophy that guides the good folks at Klim HQ in Rigby, Idaho.

Why You Should Be Layering

Temperatures often swing widely between nippy in the morning, sweltering hot in the afternoon, and downright frigid at night. Layered up to face the frosty morning temperatures, you’ll have to peel off a layer or two when the sun rises during the day. 

To be effective across a wide temperature range, your riding gear must be a multi-tiered system consisting of base, middle, and outer layers, offering flexibility and versatility.

Layering your clothing allows you to regulate your body temperature in response to changes in the weather and temperatures that affect your comfort and safety. 

It’s important to stress that, beyond comfort, layering improves safety. Overheating or shivering with cold impacts your alertness and impairs your judgment, affecting your reaction time considerably.

Why Technical Garments are Better for Layering

Many motorcyclists typically spend most of their wardrobe budget on helmets, jackets, boots, gloves, and perhaps motorcycle jeans when they realize that regular jeans don’t offer protection. 

When budgeting for riding apparel, you may overlook the underlying layers since they can be readily sourced from your ‘regular’ wardrobe. However, casual clothing performs not nearly as well as technical apparel specifically designed for motorcycling or snowmobiling. 

Up in the mountains, at high altitude, the weather is about as predictable as a cat on catnip—better be ready for anything. Half a century of riding has taught me that skimping on gear is like asking for trouble. It’s not just about comfort; it’s about survival. This notion was rubbed in my face the hard way. Let me elaborate, as there are lessons to be drawn from my experience.

A Cautionary Tale

Once upon a time, I got stuck in a blizzard after a front tire blow-out on Chang La Pass, at 17,590 ft one of the highest passes of the Himalayas in Ladakh, India. While removing my front wheel, low-drifting dark clouds appeared menacingly over the pass. Moments later, howling wind and squalls of driving snow forced me to halt working on the bike. 

Seeking shelter from the raging blizzard, I hunkered down behind the bike and wrapped myself in an aluminum foil survival blanket my son had put in my emergency kit. At the time, I laughed at his initiative, telling him I had zero intention of getting myself into life-threatening trouble. 

I realized I couldn’t have been more wrong, as I huddled next to my bike, shivering like a chihuahuha on crack. The reason I was trembling from hypothermia was that my cotton t-shirt acting as the base layer was soaked with sweat from lifting the bike onto a rock and removing the front wheel. At over 17,000 ft, the air was so thin (low on oxygen) that this task required enormous effort, leaving me sweaty and breathless. If it weren’t for the survival blanket, I might’ve succumbed to hypothermia due to the wet cotton base layer sucking the warmth out of my body. 

Why Cotton Kills

Although breathable, non-itchy, and soft, cotton is the worst-performing fabric for cold-weather gear. It’s terrible at moisture-wicking, it’s not odor-resistant, and extremely slow-drying. Because cotton is hydrophilic (water-loving), it absorbs and retains an enormous amount of water compared to its weight, the last thing you want when you’re exposed to the cold.

Continue reading if you’d like to know more about cotton’s evil character. If not, skip to here.

The Science Underlying Murderous Cotton

Our body warms the air held captive in and between the cotton fibers, insulating us from the cold. Cotton fibers are tiny hollow tubes, AKA capillaries. Through a process called capillary action*, these microtubes suck up moisture like a straw does with liquid, displacing the air trapped inside the fibers when they’re dry. Cotton clothing touching your skin absorbs your sweat like a sponge, losing its insulating capacity when the hollow fibers become waterlogged. 

*Capillary action is the propensity of a liquid to flow through narrow spaces without regard to external forces like gravity. It depends on a complex process of interactive forces like osmotic pressure, the liquid’s surface tension, the solid material’s surface energy, and the molecular bonds’ strength between them.

Without any air trapped between and inside the hollow fibers, the lack of insulation will cause you to feel cold. Even worse, your body heat will dissipate through convection from the wet base layer to the outside layers. 

Its strong capillary property makes cotton absorb up to 27 times its weight in water. This explains why cotton garments feel very heavy when soaked and why they pull body heat away at an alarming rate. The greater the cold liquid mass in contact with your skin, the faster you lose body heat through outward convection.  

We easily underestimate how dangerous wet cotton clothing can be. Generally, you lose about 2% of your body heat to convection. However, when your skin is covered with wet cotton clothing, your body loses 10%–15% of its heat. Add heat loss from evaporation and you see why hypothermia can occur even at 60℉/15℃.

Wet cotton dries very slowly as it holds onto water due to the strong capillary action. Your body loses heat rapidly if you don’t change out of your wet cotton clothes. Without insulation, your body can’t maintain its core temperature when exposed to the cold. 

The excessive heat loss and resulting drop in body temperature can lead to disorientation, hypothermia, and potentially death. It’s a common misconception that hypothermia only happens in freezing weather. The risk of hypothermia also exists in temperatures well above freezing, especially if your body is exposed to wind. Hypothermia occurs when your body loses heat faster than it can produce heat, causing your body temperature to drop to dangerously low levels. 

With the lesson learned from the Himalayan survival experience, I upgraded my wardrobe to deal with extreme temperatures from desert to Arctic conditions. In the following years, I put my technical layering wardrobe to the test in extreme conditions more times than I’d like to admit. 

Unintentionally, I found myself riding again in a blizzard in the Alvord Desert in S.E. Oregon, freezing fog at night on a mountain pass in the French-Spanish Pyrenees, and mid-winter in the Himalayas in the northwest of Vietnam. These journeys started under sunny skies, but each time I ran into freezing weather, testing my layered gear to the limit. I’m glad to say the Klim technical base and mid-layers saved my bacon.

A Short Digression on Synthetic Layers

By contrast, quick-drying synthetics used for activewear barely hold water. They are popular for sports as they excel at wicking moisture away from the skin and keeping your body temperature stable. 

Synthetic fibers such as polyester are virtually non-porous and hydrophobic (water-hating). Polyester absorbs little or no water, but it adsorbs it quite well (find out about the difference in the next section). 

Once the fibers are spun and woven, capillary action drives moisture to the surface. Synthetic fabrics developed for performance wear are made of tiny fibers aimed at controlling the moisture-wicking properties of the finished fabric. 

Click here to read more about synthetic insulation materials used in motorcycle gear. 

Understanding Moisture Wicking: Adsorption vs Absorption

Following is a short scientific explanation of how moisture wicking in fabrics works.

Absorption occurs when a substance permeates another, for example, when a sponge soaks up water. Absorbent materials have plenty of internal storage capacity to soak up and retain water.

Adsorption is a lesser-known physical phenomenon, but it’s essential to understanding how moisture-wicking works. When a substance, usually a liquid or gas, is spread evenly over the surface of another, usually a solid – we refer to it as adsorption. Adsorption keeps water sticking to a surface without penetrating it. It’s easy to remember the meaning of adsorption if you think of the words ‘adhesion’ or ‘adhesive’, i.e., sticking to the surface.

Moisture wicking is about keeping water moving. If a fiber easily absorbs water, it can’t transport that moisture effectively since it’s trapped in the fiber. Think of cotton’s great capacity to absorb and retain water. There’s no fast-acting force to extract the water from the cotton fibers and pull it to the fabric’s surface, and thus the garment remains wet. Evaporative cooling happens while moisture is still in contact with your skin, extracting your body heat. 

The importance of moisture wicking is to quickly transport sweat away from your skin before it evaporates and causes excessive body heat loss.

Technical Layers: Protection, Insulation, Ventilation, and Breathability

Layering with quality technical riding gear will always outperform layering with casual clothes by a large margin. Designed to act synergistically and enhance their joint performance, the base and mid-layers combine with the outer shell, forming an integrated system that optimizes protection, insulation, ventilation, and breathability. Let’s look at these functions in detail.

Protection

Protection is traditionally the role of the first line of defense, the outer shell, which is fitted with impact-absorption padding and abrasion-resistant fabrics or leather at the impact-prone zones.  

But that’s not always the case anymore. In recent years, advances in gear design, materials science, and production technology have led to the emergence of technical base and mid-layers that offer highly effective impact and abrasion protection. Let’s have a look at what is available.

Body Armor

If you’re an enduro or dual-sport rider, you probably prefer to wear separate body armor under a motocross jersey or a light enduro jacket, depending on the weather. Body armor comes in several forms: 

Chest Protector

The body armor popular with motocross racers is the hard-shell chest/back-protectors, AKA “roost guards”, covering the thoracic area to protect the spine, chest, and ribs. Shoulder and elbow protection pads may or may not be attached to the chest/back protector. The physical intensity of motocross racing requires an“open” chassis that offers plenty of ventilation without compromising protection and safety. 

Body Protection Jacket

Body Protection Jackets, AKA Pressure Suits, have become “standard issue” in the off-road community. Rally racers and enduro/dual-sport riders rely on these jackets for protection in the event of a get-off, which happens regularly. These tight-fitting jackets feature open-spaced mesh fabric and hard plastic protection pads on impact-prone zones. 

These pressure suits have also become popular with ADV riders and RTW travelers, especially when riding offroad when it’s hot. Throw a puffer jacket and wind/rainproof shell over a body protector when it’s raining and cold, and you’re good to go.

Pressure suits have been my go-to protective gear for the past twenty years when riding my enduro and dual-sport bikes. For long-distance off-road adventures, I often combine a pressure suit with the Klim base and mid-layers under my riding jacket and pants, depending on the terrain and expected weather.

CE AA/AAA-rated Protective Base/Mid-Layers

Alternatively, technical riding gear brands offer a growing assortment of protective base and mid-layers with integrated impact and abrasion protection. Thanks to innovative material technologies, these base/mid-layers allow you to ride in your own style of casual clothes without giving up protection. 

This gear trend is becoming increasingly popular with street riders and urban weekend warriors whose fashion sense requires donning attire that match the style of the café racers, scramblers, and retro-style bikes they ride.

The CE AAA-rated protective mesh base layers like the BOWTEX Elite Shirt and Leggings are prime examples of this growing trend of protective base and mid-layers, made possible by recent advances in high-tech fabric and PPE technology. 

For a year and a half, I’ve been wearing a Bowtex shirt and leggings as standalone riding gear when it’s hot, and under my casual clothes when it’s colder, and it’s safe to say I’m a convert. Wearing the Bowtex mesh gear as undergarments allows me to show up for a business meeting or a lunch with friends without anyone even realizing I rode my motorcycle to the rendez-vous.

The Dyneema fabric used by Bowtex feels soft and pleasant on the skin and flows air exceptionally well. If you care about your safety on the road and in city traffic, Bowtex gear is a wise investment. At least, if you prefer to look like you, instead of like a Power Ranger when you get to your destination.

Impact-Protection Base Layers 

Klim offers another option for protecting your body and limbs from painful impacts: The compression Klim Tactical Shirt, Shorts, and Pants. These protective next-to-skin base layers fit perfectly under any mid-layer and outer shell. 

Klim’s Tactical riding gear product line is equipped with Perforated XRD® Extreme Impact Protection articulated padding in all the high-impact zones.

But even on my ADV journeys, I like to wear the Klim Tactical Shorts as additional protection for my hips, thighs, and tailbone under my Klim Badlands Pro A3 Pants, already equipped with excellent D3O impact protection pads. Perhaps it’s overkill, but you can never have too much protection when you go down. Trust me, I’ve learned it the hard way. 

When embarking on a dual-sport ride in cold wet weather, my layering system combines the Klim Teton Merino Wool Gear and Klim Tactical Gear with my Gore-Tex Klim Traverse Jacket and Pants. 

If you’re riding in the desert or during summer, the highly-ventilated mesh Klim Baja S4 combo is a good outer shell to combine with your base and mid-layers when the temperatures drop.

The reason I like wearing Klim’s highly breathable, moisture-wicking, Tactical base layers is that their compression function supports your body, reduces muscle fatigue, and enhances your comfort, making long rides more enjoyable. If it’s cold, I wear Klim Teton Merino Wool Boxers or Pants under my compression Klim Tactical Shorts or Pants. It works a treat.

Airbag Vests

Unless you’ve been living under a rock, you’re no doubt aware that there’s a new kid in town who is rapidly inflating his wealth through the protection racketeering business: The Airbag Vest.

As the world’s leading “Layering Company”, Klim offers the Ai-1 Airbag Vest, and its desert-racing twin, the Klim Ai-1 Rally Airbag Vest. This protective vest can transform itself from a slim silhouette to a bulging fatso in the blink of an eye. 

Klim’s high-tech airbag vest offers the ultimate protection. The inflation is electronically controlled by a microprocessor receiving signals from crash detection sensors that are processed through algorithms driven by artificial intelligence (AI).

Although I have no intention of falling off a motorcycle for the sake of testing the efficacy of an airbag vest, I’m convinced that airbag technology is the new gold standard in PPE for motorcyclists. With a price tag similar to a decent helmet, you have no excuse for not safeguarding yourself from bodily harm with an airbag vest. 

If highly-paid MotoGP racers bet their lives and fast-paced million-dollar careers on this AI-driven smart technology, then it’s good enough for me. The Klim Ai-1 Airbag Vest must be popular, because it’s often out of stock. But I hope to have one soon for review. Stay tuned!

Ventilation  

Ventilation is critical for avoiding overheating when riding in hot weather. It’s primarily a function of the outer shell, the first and often only windproof barrier, and the gatekeeper for ventilation. 

The base and mid-layers also play an important role in ventilation. The design, quality, compatibility, and choice of layer materials and vents determine how effective the ventilation of the entire layering system is. 

A layering system consisting of base and mid-layers designed to be used jointly in a modular fashion performs better, exemplified by Klim’s collection of technical layers.

There are three approaches to beating the heat with ventilated technical layers, using mesh fabrics and vents.

• The first method, consisting of protective mesh jackets and pants, offers the most effective ventilation. For example, no mesh outer shell that protects against impact and abrasion lets more air through than the CE AA-rated Klim Marrakesh or Klim Baja S4.

• The second method consists of mesh base/mid-layers that offer the highest level of impact and abrasion protection like the CE AAA-rated Bowtex Elite Shirt and Elite Leggings discussed earlier.

The advantage of these über-protective base/mid-layers made from Dyneema is that they allow you to ride in your own (casual) dress style (are you listening, vintage/scrambler/cafe racer owners?) without giving up protection. 

Although intended as base and mid-layers, riders increasingly wear the Bowtex apparel as outer shells when it’s hot, including myself and Evan, the publisher of this website, and Sarah Lezito, the world’s best female stunt rider.

• The third method consists of conventional outer shells ventilating via opening the main zipper, the zippered vents, and mesh panels on the jacket and pants. These all act as the controls of your vestimentary “air conditioning”. 

The vents’ design, number, size, and configuration on the garment determine how well the outer shells ventilate. With 12 vents in the jacket and 6 in the pants, the Klim Badlands Pro A3 is the best-ventilated, 4-season, all-weather ADV suit on the market.

Breathability and Moisture-Wicking

Compared to casual clothing, technical base layers are more effective in keeping you comfortable and dry through their engineered breathability, moisture-wicking properties, and choice of materials. 

By letting air through and wicking away perspiration from your skin, the layers shed heat through convection and evaporation. This is important when riding in hot weather, as you might be tempted to shed the outer layer or wear a light, less protective shell in an attempt to stay cool. 

Insulation

The advantage of technical garments becomes apparent when temperatures drop: The thermal insulation properties of technical layers do not suppress breathability when ventilation is closed off to prevent you from getting cold. 

To be effective, insulation has to have a level of breathability and moisture-wicking properties. Without these properties, your perspiration can’t evaporate and your clothes will get clammy and you’ll start feeling cold.

Opening or closing vents and adding or peeling off base layers and mid-layers is the most effective way to regulate your body temperature. 

Beyond Insulation: Electrically Heated Garments

Electrically-heated garments are becoming increasingly popular thanks to the advent of USB-C rechargeable compact lightweight batteries. The battery-powered heating technology is now applied across a range of garments, from gloves to shirts, jackets, pants, and socks. 

The Klim Aggressor eFire Heated Shirt is a battery-powered base layer that keeps your body warm through the use of heating filaments integrated in the fabric panels on the chest and upper back. The Klim Override eFire Vest is a technical mid-layer that combines 3M Thinsulate insulation with electric heating technology,

Technical Layering for the Heat

While dressing for the cold is a matter of layering up, intuitively you’ll want to shed layers to cope with the heat. Wearing as little as possible is the name of the game when it’s stinking hot, right? We want to maximize ventilation and evaporation. The less you wear, the greater the cooling effect from the riding wind. This is true, but only to a certain point, beyond which the heat is too high for the wind to have a cooling effect. 

When you’re riding in temperatures beyond 105 °F (40 °C), you’re better off shielding your body from the hot wind as you risk heatstroke and excessive loss of sweat through evaporation.

In addition to ventilated or mesh base and mid-layers, advances in fabric technology have resulted in technical base layers that have active cooling properties. 

KLIM’s second generation of Aggressor -1.0 Cooling Base Layers use chemical-free fabric technology for cooling, moisture-wicking and evaporation, making this material unlike other cooling and sweat-wicking fabrics on the market. The collection includes long sleeve and short sleeve shirts, pants, and briefs, all optimized for moisture-wicking, breathability, and cooling for motorcyclists and outdoor activities when it’s hot.

I admit that I was more than skeptical when I read the marketing pitch for Klim’s Aggressor -1.0 series of technical cooling garments. I was convinced that it was hyperbolic marketing speak from an overly enthusiastic advertising copywriter. Cooling garments made from chemically treated fabrics that induce a cooling effect become ineffective with use and washing over time. But here comes Klim asserting that their cooling garments don’t rely on a chemical substance but on a proprietary chemical-free cooling fabric technology that never loses its effectiveness.

Similar to my experience wearing Merino wool for the first time, I had another epiphany moment when I first wore the Klim Aggressor -1.0 Long Sleeve Shirt. If you haven’t experienced it, it’s hard to believe how well Klim’s chemical-free fabric technology works in terms of cooling, moisture-wicking and evaporation. Unlike other cooling and sweat-wicking fabrics on the market, Klim has come up with a unique moisture-wicking fabric that actively pulls sweat away from the skin, promoting rapid evaporation and a lasting cooling effect.

After almost two years of intensive use, this shirt’s cooling effect hasn’t worn off, as it’s just as noticeable as the first time. The Klim Aggressor -1.0 Cooling Garments deliver above and beyond what the sales pitch promises on Klim’s website. Ignore at your own risk, but if you want to beat the heat, trust me, the Aggressor -1.0 series are worth every penny.

The Alpinestars Cooling Vest is an indispensable hot weather riding accessory that uses water to regulate the rider’s core temperature. Stretch elements in the vest ensure a good fit and full benefit from airflow and water cooling – even during the most strenuous off-road maneuvering. Easy to fill water port makes for quick, no-mess fill-ups and minimal downtime. Wide open-air perforations function as gussets to guarantee that the Alpinestars Cooling Vest always keeps its shape. 

Features: 

• Liquid cooling system that evenly releases cooling water droplets (mist) against the rider’s midsection 
• Regulates vascular system and limits the effect of heat exhaustion
• Incorporated stretch inserts for fit and improved ventilation 
• Designated air ports allow for airflow and breathability 
• Lightweight with a refillable water chamber for easy continuous use
• Three-layer textile construction with moisture-wicking fleece lining

Merino Wool: A Wicking Good Fiber

Admittedly, I discovered the exceptional qualities of merino wool late in life. For decades, I shunned wool and only wore cotton or synthetic layers under my riding gear. Until a few years ago, wearing woolen clothing was unthinkable, due to being haunted by boyhood nightmares. I equated any kind of wool with the hateful itchiness of the coarse woolen sweaters my brothers and I had to wear because our mother lovingly knitted them for us. Little did I know that… 

… not all woolen yarns are created equal.

Boy, was I in for an eye-opener the first time I wore the Merino wool-based Klim Long-Sleeve Shirt, Pants, and Boxers in direct contact with my skin. I was shocked to discover how warm and silky soft these body-hugging undergarments felt. How did I miss out on this for all these years?

This begs the question: what makes merino wool so unique and special? If you’re interested in learning what makes this natural fiber stand out compared to other—coarser—wool varieties and synthetics, then read the following section. Otherwise, skip to the section on All You Need to Know about Puffer Jackets.

The Exceptional Qualities of Merino Wool

Of the more than 1,000 sheep breeds in the world, Merino sheep produce the finest fleece possessing many outstanding qualities that make it commercially the most valuable wool.

Qualities / Advantages:

• Softness: Merino wool is extremely soft, providing a luxurious itch-free feel against your skin. It’s not prickly like other, coarser wool varieties. Merino fibers are very thin and soft, so they bend out of the way when brushing up against your skin. The thickest merino wool fiber measures 23 – 24.5 microns, which is only ⅓ to ¼ of the diameter of a human hair (75 to 100 microns on average). 

• Elasticity: Merino wool has exceptional elasticity thanks to its crimped, springy fibers offering excellent bounce in fabrics. Merino wool garments are flexible, stretchy, wrinkle-resistant, shrink-resistant, and retain their shape, even after long-term repeated use.

• Thermal insulation: One of the key reasons why merino wool fabric is highly regarded in the activewear/outdoor clothing industry is its exceptional insulation properties. Thanks to its natural loft, merino wool preserves body heat, trapping warm air between its crimped fibers. The wool’s coiled hair fibers also create microscopic pockets that trap warmth. 

• Stays warm when wet: Merino wool is one of the rare fabrics that can generate heat while it dries. When it gets wet, water is trapped in the porous fibers. The hydrogen bonds in water break down inside the wool’s fibers, creating an exothermic chemical reaction that generates heat. Experiments have found that one kilogram of merino wool can produce as much heat over eight hours as an electric blanket.

• Breathability/Thermo-regulation: Since merino wool breathes very well, it helps regulate your body temperature. When it’s cold outside, its fibers’ natural coils, crimps, and curves trap air, insulating you. When it’s warm outside, it transports perspiration quickly away from the skin, preventing overheating and helping to keep you cool and dry. Its breathability and moisture-wicking ability are crucial to keeping your body at a stable temperature.

• Moisture-wicking: Merino wool keeps you dry and sweat-free. Merino wool pulls perspiration away from your skin as a vapor (pre-sweat). Merino fibers are inherently porous. They’re composed of tiny plates that moisture vapor can get in between and transport to the outer layers—preventing you from feeling wet, cold, and clammy.  

Unlike synthetic fabrics, Merino wool has the remarkable ability to adsorb moisture without feeling wet, to a certain degree. It can adsorb up to 30% of its weight in moisture without feeling damp, keeping you dry even in humid conditions. Its limited capillary action doesn’t displace the air trapped in the micro air pockets in its coiled fibers.

In contrast, synthetic fabrics are not porous and wick sweat away as a liquid, not a vapor. Your body has to heat up the sweat/liquid to evaporate it—making you feel clammy in colder weather. Merino takes the sweat evaporation step out of the process, helping you stay warm and dry.

• Good For Layering: The colder it gets, the more you’ll need to layer to boost insulation. 

The advantages of multiple layers are threefold:

• Firstly, in contrast to one thick layer, multiple layers offer adjustability. Adding or removing layers allows you to manage the level of thermal insulation necessary to preserve or shed heat and hence regulate your body temperature. 

• Secondly, multiple layers create a more effective thermal insulation barrier. Air gets trapped between the layers and within the merino fabric of each layer. 

• Thirdly, more effective wicking: if all layers are merino wool, they wick perspiration away from the skin to the outside of your gear as vapor instead of liquid—helping to keep you warm and dry. Adding a synthetic layer into the mix would throw up a barrier to the sweat-vapor escape route, causing you to get cold and clammy.

• Odor resistance: Compared to synthetic garments that stink unbearably by the end of the day, merino wool absorbs odor caused by bacteria—trapping their smell and keeping them from building up, even after prolonged use, thanks to its wax coating.

• Antimicrobial and antifungal properties of Lanolin, merino wool’s natural wax coating, prevent the growth of bacteria that cause bad smells, making it great for multi-day use without washing. 

Lanolin is a natural wax that coats the wool of merino sheep and provides multiple benefits, including: 

• Waterproofing: Lanolin helps repel water and protects the sheep’s skin from harsh climates. 
• Antibacterial: Lanolin prevents bacteria from forming, even in wet environments.
• Odor resistance: Merino wool’s natural lanolin repels odor-causing bacteria. 
• Softness: Lanolin helps keep the wool soft. 
• Elasticity: Lanolin helps merino wool stay elastic. 
• Mold and mildew resistance: Lanolin helps Merino wool resist mold, bacteria, and mildew. 

• UV protection: Merino wool offers natural protection against the sun’s harmful UV radiation as its fibers have a built-in UV absorption capability. 

• Flame-retardant/Self-extinguishing: If you occasionally sit around a campfire, it’s reassuring that Merino won’t burn or melt like nylon or polyester when sparks or hot ashes land on you. 

• Sustainability: Merino wool is a 100% natural fiber, making it an environmentally friendly, renewable, and 100% biodegradable material. Merino wool disappears after about 12 months in or on the ground, disintegrating its fibrous protein and releasing carbon and nutrients into the soil. 

• Anti-static: Since Merino wool absorbs moisture, it’s less likely to cling to the body and cause static electricity.

• Hypoallergenic
• Lightweight
• Mothproof

Disadvantages

• Merino wool is significantly more expensive than synthetic materials. 

• Merino wool is less resistant to wear and tear than synthetic materials. 

To improve durability, manufacturers produce fabric blends combining merino and synthetics, merging their qualities while offsetting their disadvantages. 

Klim Teton Merino Wool apparel is made from a blended technical fabric comprising 80% merino wool and 20% nylon, making it more durable than pure merino.

Taking Care of Merino Wool

Merino wool will last longer and retain its outstanding qualities and performance if you respect the following instructions when washing:

• Turn the clothes inside out
• Use the most gentle wash cycle
• Use a maximum temperature of 86˚F/30°C
• Select a low spin speed (600 – 800 rpm)
• Don’t use fabric softener, bleach, or bio-washing powder
• Don’t put the clothes in the dryer
• Ideally, dry the garment in a horizontal position

All You Need to Know about Puffer Jackets

Puffer jackets are the warmest mid-layer options, outperforming wool or polar fleece. They keep you warm the same way goose down keeps geese warm, by trapping pockets of warm air close to the skin, keeping warm air in and cold air out. They are stuffed with natural or synthetic down that mimics natural down or a combination.

Despite the growing popularity of synthetic insulation materials, duck or goose down remains the warmest, lightest, and most compressible filling for puffer jackets. This is surprising given synthetic materials have made tremendous technological progress while down hasn’t changed since the first down jacket was sold in 1936.  

Natural Down vs Synthetic Insulation

The first distinction we must make is between puffer jackets filled with synthetic insulation and natural down. Both have their pros and cons. 

Although many outdoor/activewear brands praise the qualities of synthetic insulation, goose or duck down still outperforms it in cold, dry conditions. Down is ultralight, ultrawarm, and ultracompressible. 

Down is lighter, less bulky, packs smaller, and weight-for-weight it’s warmer than synthetic insulation. 

But down’s major weakness is that it fails to insulate when wet and dries slowly. In contrast, synthetic insulation maintains its insulating power in damp conditions. Down is also a lot more expensive than synthetic insulation.

Down’s artificial alternative is a synthetic filling designed to mimic the softness and insulating properties of natural down. Typically made from materials like polyester microfibers, the synthetic alternative is hypoallergenic, making it an excellent choice for those with allergies.

Synthetic fills have no equivalent test to the down-fill power rating system, and each brand of synthetic insulation has unique characteristics. So, it’s impossible to compare insulation efficiency of natural down to any synthetic fill or between two different synthetic fills.

Comparison of Pros and Cons of Down vs Synthetic Insulation

The most common criticism of down insulation is its tendency to clump up and lose loft when it gets wet, thereby losing its insulation properties. 

Proprietary technologies have been developed over the years to treat down at a microscopic level with a water-resistant application. This treatment allows goose down to resist light moisture without compromising its loft. I walked in drizzling rain on several occasions with my Klim Maverick Down Jacket without the down getting wet. This said, it benefits from a water-repellent outer shell fabric.

However, if submerged in water or exposed to heavy rain, even treated down will get wet, so it’s imperative to keep your down-filled puffer jacket dry. 

Down vs Feathers

Nature’s best insulator, down is the light, airy, soft undercoating found under the visible feathers of waterfowl such as ducks and geese. Down consists of spherical clusters of fluffy, wispy filaments growing from an undetectable central quill point, similar to a dandelion pod. In contrast, feathers have a long hard quil from which two rows of close-knit fibers sprout.

Down is prized for being light, easy to compress, resilient, long-lasting, breathable, and above all, insulating better than any man-made material. It’s the insulation of choice in cold, dry conditions, or when reducing weight and saving space are top priorities. These qualities are high on the specs wish list of ADV riders.

Feathers are the plumage, or outer growth, of birds. Feathers trap much less air than down as they don’t loft and are not spherical. 

Feathers consist of a hollow quill shaft (or stem) with a series of fibers extending from each side. The pointy end of a feather’s stiff quill shaft makes it prickly, and thus less desirable for garments worn close to the skin.

Why Mix Feathers with Down?

Manufacturers often blend down and feathers, indicated by a percentage ratio of down to feathers. For example, the Klim Maverick Down Jacket contains 90/10 goose down, meaning 90% down and 10% feathers. But if down offers superior insulation and softness, why not opt for 100% down filling instead of mixing feathers into the blend? 

Feathers in goose-down puffer jackets serve several key purposes:

1. Loft and Insulation: While down itself provides excellent insulation, feathers play a crucial role in maintaining the loft or volume of the jacket. Feathers help to create structural air pockets within the down cluster, which trap warm air and prevent cold air from penetrating. This enhances the jacket’s overall insulation properties.
2. Durability and Structure: Feathers provide structural support to the down cluster, preventing it from clumping together and losing its insulating efficiency. This helps to maintain the jacket’s lofty shape and durability over time.
3. Cost Reduction: Feathers are generally less expensive than pure down, so adding them to the filling can help reduce the overall cost of the jacket without significantly compromising its insulating properties.

The 90/10 blend is the ‘golden ratio’ for high-quality goose-down puffer jackets. This means 90% of the filling is down and 10% is feathers. This ratio offers a good balance between insulation, durability, and cost. Adding more feathers would lower the production cost, but would also reduce insulation and warmth. Fewer or no feathers would affect the loft and durability.

Ultimately, the ideal ratio depends on the specific needs and preferences of the manufacturer and the target market. The 90/10 blend is a common ratio for top-quality goose-down puffer jackets of high-end brands.

What is Fill Power and why is it important?

Down Fill Power is a measure of the loft of down and indicates its quality and warmth or insulating power. It’s the volume in cubic inches that one ounce of down takes up; higher quality down lofts to a higher volume.

The rating scale ranges from 300 to 900 or higher, with most common down products having a rating of 400 to 500. 

It’s measured in a lab by compressing one ounce of down in a glass cylinder. The down’s “loft” indicates its resilience or ability to bounce back after being compressed for 60 seconds. The fill power indicates how much air the lofted down can trap. 

YouTube: How fill power is measured

The fill power scale typically ranges from 300 to 900, with higher fill power indicating better quality down, more loft, more air trapped, and thus warmer. The higher loft also means the down is more resilient and thus lasts longer.

Fill Power vs Fill Weight 

Although fill power indicates the quality of the down filling, it’s not the only factor determining how well a down jacket protects you against the cold. 

Higher fill power numbers indicate greater loft and insulating efficiency. But that down fill power does not tell you how warm a jacket will be because other factors affect warmth. 

The Fill Weight, or how much down is used to fill the puffer jacket also affects how warm it’ll keep you. 

Premium goose down can reach fill-power ratings of 900 to 1000, while duck down can achieve fill-power ratings of maximum 750 or 800.

Comparing puffer jackets is not an easy task, because very few brands report the jacket’s fill weight, which affects insulation and warmth as much as fill power.

In theory, a puffer jacket filled with 100 g of 800-fill-power down would offer the same warmth as one with 200 g of 400-fill-power down; it would also compress to about half the space. 

But any simple formula for warmth calculation won’t account for differences in how the down is distributed within baffles and around the jacket. 

Baffle Box vs Sewn-Through

Another factor influencing the warmth of a puffer jacket is the construction method, namely if the down is contained in baffle boxes or sewn-through pockets. 

The Baffle Box construction is warmer than sewn-through construction. 

The internal 3-dimensional compartments created by baffle box construction allow for a larger volume, more even fill distribution, and greater loft, resulting in better insulation and greater warmth. 

The extra stability of the baffle box design reduces wear and tear on the stitching and loss of down, increasing the jacket’s durability and lifespan.

The three-dimensional structure of the baffle box with individual chambers helps to keep the filling evenly distributed. It also makes for a flatter surface and allows the fill to loft fully at the edges of its chamber, reducing cold spots. 

The disadvantage of the baffle box design is that it is more expensive: it requires more labor and materials, making it a high-quality construction method with a higher price tag. 

The Sewn-Through Box construction stitches the jacket’s lining and outer shell together, reducing the 2-dimensional box volume available for holding the down filling. This results in a lower fill weight and thus less insulation and warmth. 

In addition to the smaller boxes, the sewn-through construction creates a ‘cold bridge’ at the stitching, causing heat loss. The stitching holes also offer an escape path for the down and feathers, resulting in the jacket shedding its insulation over time. The sewn-through stitching imposes more wear and tear on the thread and fabric.

My old down jacket was of the sewn-through type, and from day one, it shed its feathers through the stitching holes at an alarming rate. Over the years, I left a trail of tiny feathers and down tufts across various continents.

The sewn-through construction allows for a budget-friendly puffer jacket as its production requires less labor and less material. Another advantage is that the down won’t shift as easily as the compartment is smaller than a baffle box. 

Goose Down vs Duck Down

Down insulation has typically been sourced from geese. But the increasing demand has driven up the price of goose down. Compared to geese, the duck farming industry and market is much bigger and duck down production is therefore much larger and cheaper than goose down. As a result, many manufacturers of down apparel switched to duck down in recent years .

Its lower cost is duck down’s only advantage, as its performance is inferior to goose down. Geese are bigger birds and their down tufts are much larger than duck down. Even for tufts of the same size, the insulation power of goose down is 15% higher than that of duck down. 

The fill power rating scale also illustrates the superiority of goose down. Duck down fill power ratings are in the 300-400.

Premium goose down can reach a fill power rating of up to 1000, while duck down can achieve a maximum of 750 or 800.

The advantage of goose down’s higher fill power is that it requires less down to fill space and achieve the same insulation or warmth as a jacket with duck down filling (assuming the fabrics and other features are comparable in weight, construction, and quality).

Premium fill-power goose down commands a premium price. It’s used to keep puffer jackets ultralight, ultrapackable, and ultra-insulated. So if you’re trying to save weight and space in your motorcycle luggage system or you want a stylish warm winter jacket that is guaranteed to keep you warm, an 800-fill-power puffer jacket like the Klim Maverick is your best bet. 

Synthetic Insulation Materials

Several alternatives and brand names exist for synthetic insulation fabrics that offer similar performance to Merino wool blends. These proprietary synthetic materials are popular for their lightweight, breathable, and insulating properties. They stand out for their fast moisture-wicking and quick-drying performance.

These synthetic alternatives offer varying levels of warmth, breathability, water resistance, and compressibility. Following you’ll find a list of synthetic insulation brands and technologies used in outdoor and motorcycle gear:

1. PrimaLoft

• Overview: PrimaLoft is a synthetic microfiber thermal insulation material developed as an alternative to goose down. Created for the U.S. military in the 1980s, PrimaLoft offers high warmth-to-weight performance and retains heat even when wet. It’s one of the most popular synthetic insulations for outdoor and performance gear, known for balancing warmth, compressibility, and water resistance.
• Key Features:
  • Lightweight with excellent thermal efficiency
  • Maintains warmth even when wet
  • Highly compressible, easy to pack into small spaces
  • Soft and comfortable feel, similar to natural down
  • Available in multiple versions for different applications (PrimaLoft Gold, Silver, Black)
  • Made from recycled materials in some versions (Eco-friendly options)
• Used in:
  • High-performance motorcycle and outdoor gear (jackets, gloves, sleeping bags)
  • Mid-layers and outerwear for activities like skiing, hiking, and motorcycling
  • Cold-weather (motorcycle) gloves and footwear
  • Insulated liners in (motorcycle) jackets and pants

2. Thinsulate

• Overview: Developed by 3M, Thinsulate is a thin and lightweight synthetic insulation known for its superior ability to trap heat without adding bulk. The name comes from “thin” and “insulate,” and it lives up to its name by offering warmth in a thin profile. It’s commonly used in a wide range of applications, from casual apparel to outdoor performance gear.
• Key Features:
  • Very thin, lightweight insulation with a high warmth-to-weight ratio
  • Traps air molecules between fibers for effective insulation
  • Available in multiple thicknesses and insulation grades
  • Maintains insulation properties even in damp conditions
  • Breathable and moisture-wicking
  • Often used in combination with other insulation layers for extreme cold-weather gear
• Used in:
  • Motorcycle gloves, winter gloves, hats, and boots
  • Motorcycle mid-layers, lightweight insulated jackets and pants
  • Outdoor sports gear (skiing, snowboarding, hiking)
  • Workwear for cold environments
  • Automotive applications (insulated car seats and interiors)

3. Polartec Alpha

• Overview: Originally developed for U.S. Special Forces, Polartec Alpha is known for its active insulation properties, which allow for better breathability while providing warmth.
• Key Features: Breathable, quick-drying, designed for dynamic activities where fluctuating temperatures are common.
• Used in: Outdoor gear, jackets, and mid-layers.

 PrimaLoft, Thinsulate, and Polartec Alpha are the most popular choices for synthetic insulation in motorcycle apparel applications. Valued for their warmth, lightweight performance, and moisture resistance, they are ideal for a wide variety of outdoor and cold-weather applications, including motorcycling.

If you’re looking for non-motorcycle brand alternatives, brands like Climashield, Coreloft, and Thermore offer comparable options. Each has its own strengths depending on the activity, climate, and gear requirements, and all can provide warmth, durability, and weather resistance without the bulk of traditional insulation. For motorcyclists, particularly, having flexible, lightweight, and weather-resistant insulation is key to comfort on long rides through varying conditions.

4. Climashield

• Overview: A continuous filament synthetic insulation, known for its durability and ability to retain loft even after repeated compression.
• Key Features: Highly compressible, durable, retains warmth even when wet, often used in military gear and outdoor applications.
• Used in: Sleeping bags, outdoor clothing, and some motorcycle gear.

5. Coreloft by Arc’teryx

• Overview: Developed by Arc’teryx, Coreloft is a proprietary insulation used in their jackets and other outerwear.
• Key Features: Highly compressible, low bulk, and provides efficient warmth.
• Used in: Arc’teryx gear, primarily in their insulated jackets and mid-layers.

6. Thermore

• Overview: An Italian company that produces high-performance thermal insulation for outdoor, active, and fashion apparel.
• Key Features: Lightweight, excellent thermal retention, and available in various versions, including EcoDown (recycled materials) and Freedom (stretch insulation).
• Used in: Fashion and outdoor brands, jackets, and activewear.

7. Thermolite

• Overview: A synthetic insulation technology known for lightweight warmth. Thermolite is designed to trap body heat and keep the user warm without adding excessive bulk.
• Key Features: Lightweight, moisture-wicking, highly breathable.
• Used in: Outdoor apparel, gloves, and mid-layers.

8. Apex by Polartec

• Overview: Apex is another synthetic insulation from Polartec designed for warmth, breathability, and lightweight performance.
• Key Features: Provides excellent thermal regulation and moisture-wicking properties.
• Used in: Mid-layers, outerwear, and activewear.

9. 3M Featherless Insulation

• Overview: Synthetic insulation designed to mimic the warmth and loft of down but with the added benefit of staying warm even when wet.
• Key Features: Water-resistant, retains warmth when damp, offers a down-like feel and compressibility.
• Used in: Jackets, sleeping bags, gloves.

10. G-Loft

• Overview: G-Loft is a synthetic insulation developed in Austria, known for its ability to combine the advantages of down and synthetic fibers.
• Key Features: High warmth-to-weight ratio, retains insulation when wet, quick drying, and durable.
• Used in: High-performance outdoor gear and tactical clothing.

11. Heatseeker by The North Face

• Overview: A proprietary synthetic insulation developed by The North Face for use in their outerwear and accessories.
• Key Features: Highly durable, retains warmth when wet, and compresses easily.
• Used in: The North Face jackets, sleeping bags, and gloves.

12. Loftech by Mountain Equipment

• Overview: A synthetic insulation developed by Mountain Equipment to mimic down’s warmth and compressibility, while maintaining its ability to stay warm when wet.
• Key Features: Highly compressible, lightweight, down-like performance.
• Used in: Mountain Equipment’s insulated jackets and sleeping bags.

13. FX Down by Montbell

• Overview: A synthetic alternative to down that provides great insulation while staying light and compressible.
• Key Features: Warmth similar to down, dries quickly, and retains insulating properties when wet.
• Used in: Montbell outdoor gear, especially jackets.

14. HyperDRY by Allied Feather & Down

• Overview: While this isn’t a synthetic insulation, it’s a water-resistant down that behaves similarly to synthetic fibers when wet, offering a combination of down’s warmth and water resistance.
• Key Features: Lightweight, water-resistant, retains loft even in damp conditions.
• Used in: High-end down jackets and sleeping bags.

Summary

All the aforementioned synthetic insulation materials are alternatives to Merino wool blends used by motorcycle gear brands like Klim and Mosko Moto for their thermal base and mid-layers. PrimaLoft, Polartec Alpha, and Thinsulate are popular synthetic insulation brands in the motorcycle gear industry, but the other outdoor gear brands offer comparable options. 

Each brand has its own strengths depending on the activity, climate, and gear requirements, and all can provide warmth, durability, and weather resistance without the bulk of traditional insulation. For motorcyclists, particularly, having flexible, lightweight, packability and weather-resistant insulation is key to comfort on long rides through varying conditions.

The post Mastering Motorcycle Gear: The Art and Science of Layering first appeared on It's Better On The Road.

Add Boreas, Aquilo, or other gods of winter into the mix, and we’ll need warm clothing under our riding jacket and pants to cope with the plummeting temperatures. Factor in the windchill, which increases dramatically the faster you go, and you’ll need to upgrade your riding outfit with several warm layers under your winter motorcycle jacket. 

You may delve into your winter wardrobe and don a flannel shirt and knitted sweater or two, but casual clothes are not nearly as effective as layering with base and mid-layers designed to work together.

If you’re as passionate about riding as we are, hibernating is simply not an option as the primal urge to go riding is too strong to ignore, even if it’s cold. But giving in to that craving doesn’t override your other primal desire. The one for which you don’t want to risk sacrificing your family jewels on Jack Frost’s ice altar. 

But fear not, “Klim Technical Riding Gear” AKA “The Layering Company” offers a range of thermal base/mid-layers to keep you warm and comfortable. And no, they aren’t just the “most hyped brand” – Klim makes the best technical gear for riding, and I’ve tried just about every piece they’ve produced.

And it doesn’t surprise me that Klim nails layering more than any other manufacturer; they are the world’s #1 snowmobile apparel brand. The folks from Idaho know a thing or two about dressing for the cold!

List of Reviewed Klim Layers

In the following long-term test, I evaluated the three base layers and two mid-layers that kept me cozy and warm on my journeys on three continents over the past year and a half. 

Boxers	Pants	Shirt
Klim Teton Merino Shorts	KLIM Teton Merino Wool Pants	KLIM Teton Merino Wool LS Shirt
Primary Rating: 5.0	Primary Rating: 5.0	Primary Rating: 5.0
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Boxers

Klim Teton Merino Shorts

Primary Rating:

5.0

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Pants

KLIM Teton Merino Wool Pants

Primary Rating:

5.0

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Shirt

KLIM Teton Merino Wool LS Shirt

Primary Rating:

5.0

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The Mid Layers I tested were the Klim Maverick Down Jacket and Klim Teton Merino Wool 1/4-Zip Shirt which I’ll get in to further down in the review. You can always slide out the Table of Contents to jump to any point in the article by clicking the button in the bottom right or sliding your finger from right to left.

I layered these technical garments under the top-of-the-line Klim Badlands Pro A3 Jacket and Pants (reviewed here) on my ADV journeys and the Klim Traverse Jacket and Pants riding my dual-sport bikes.

You can read my review of the Klim Badlands Pro A3 here. It’s the world’s first—and so far only—CE AAA-rated Gore-Tex triple-layered textile suit, which sets a new benchmark for premium, über-protective, four-season, all-weather ADV gear. 

Test Results in a Nutshell

I tested these Klim layers in frigid fall temperatures in the Alps, freezing fog in the Pyrenees, and glacial spells in the Himalayas. It was so cold at times that, if it weren’t for the multiple layers of thermal insulation, I would’ve been forced to abort the trips to avoid turning into an icicle. 

Here’s what I found:

1. The Klim layering system
   • Allows for riding in all conditions with excellent thermal performance and versatility. 
   • Makes for more enjoyable and safer riding by regulating your body temperature.
2. Merino wool offers:
   • Superior thermal insulation (more comfort with less gear)
   • Moisture wicking (sweat doesn’t mix with cold air to make you an icicle)
   • Multi-day odor resistance (HUGE when doing any adventure ride)
   • Itch-free softness next to the skin. (Trust me, a little itch can ruin an otherwise incredible trip)
3. The Maverick Down Jacket 
   • Is remarkably warm yet ultra-light
   • Packs small in one of the hand pockets
   • Doubles as a great casual jacket

Why Klim for Layering?

This review evaluates a layering system for the colder half of the temperature spectrum. An effective layering wardrobe should consist of carefully selected base layers and mid-layers that cooperate well. This is the case for the Klim base and mid-layers since they are designed to be combined in a layering system.

Worn under your protective outer shell, these layers allow you to continue riding without risking becoming an iceman or melting into a puddle of sweat. In a future review, I’ll discuss technical gear for hot-weather riding.

Unless you’re a newcomer to the “extreme sport” of dual-sport/adventure riding and snowmobiling, Klim Technical Riding Gear needs no introduction. The brand has become synonymous with garments for hard-core ADV/dual-sport/enduro/MX and snowmobile enthusiasts.

If you are a new convert to the ADV/off-road motorcycle lifestyle, know that: 

Klim is the global leader in designing, developing, and manufacturing the most advanced technical riding gear and motor sports apparel for the snowmobile and motorcycle rider.

And that’s not a hollow marketing slogan, as insiders acknowledge that Klim sets the benchmark for the motorcycle and snowmobile apparel and gear industry.

Based on its track record in successfully developing gear and apparel for extreme outdoor sports, Klim has earned its self-proclaimed title:      KLIM® – THE LAYERING COMPANY

The technical layering apparel I tested for this review uses a blend of merino wool and nylon for the base and mid-layers and goose down for the insulation of the puffy jacket.

Klim Base Layers Reviewed: Klim Teton Merino Wool

For motorcyclists, comfort is paramount, especially on long rides. But finding base layers that can handle the demands of the road – cold, heat, and sweat – can be a challenge.

Let’s start from the innermost: Enter the Klim Teton Merino Wool Boxers, a pair of technical base layer boxers designed to keep you comfortable and confident, mile after mile. Much of what I note here will be applicable to all the Klim Teton Merino Wool base layers.

This section will be low on pictures; you don’t want to look at my underwear.

Klim Teton Merino Wool Boxers

Even in my weirdest dreams, I never imagined that one day, I’d be writing a review of underwear, let alone woolen boxers. I loathed wool throughout my boyhood because of the typical itchiness inherently caused by prickly, coarse woolen sweaters.

It’s beyond an understatement to say I was skeptical when someone recommended trying out undergarments in merino wool. But lo and behold, never before did something as simple as a pair of boxers obliterate my skepticism. The softness of the lightweight merino wool fabric was equaled by the surprising fact that it was itch-free.

The snug-fitting boxers are made from an 80/20 merino wool/nylon blend, prioritizing the natural comfort and odor resistance of merino while adding nylon for durability. The flatlock stitching throughout the garment promises a chafe-free experience, a crucial aspect of any motorcycle base layer.

Hitting the Road

The true test of any base layer lies in its performance on the road. My initial impression of comfort was confirmed during the initial six-week adventure ride through varying weather conditions across Europe. 

The merino wool proved to be exceptionally breathable, wicking away moisture effectively and keeping me cool on hot days. When temperatures dipped, the wool’s natural insulating properties provided surprising warmth without feeling bulky. 

In Klim’s marketing speak, it’s referred to as “warm and cool reactive temperature regulation”. What matters is that merino wool works exceptionally well at keeping you warm when it’s cold and cool when it’s hot. 

Merino’s reactive temperature regulating capacity is a unique quality that makes it versatile. I thought Merino wool base layers would only prove their value in terms of insulation against the cold. I had not expected it to be an effective base layer keeping me cool when it’s warm. On the contrary, I thought I would quickly break out in a sweat in rising temperatures. But thanks to Merino wool’s exceptional breathability and moisture-wicking capability, I kept my cool and my skin sweat-free.

Merino wool is also known for maintaining its insulation when wet. However, as my Klim Badlands Pro A3 combo is waterproof, I never had the chance to test this quality while riding. But I did experience Merino wool’s thermal insulation performance when my Klim Teton Merino Wool Long-Sleeve Shirt got wet during a bicycle ride. It felt definitely a lot warmer compared to a cotton shirt which becomes a chill generator when wet. 

Odor Resistance Put to the Test

One of the biggest advantages of merino wool is its odor-resistant antimicrobial nature. I was rather skeptical of the claim of its multi-day odor resistance. However, it didn’t take long to make me a believer. 

After a full day of riding, the Teton Boxers remained remarkably fresh. But the amazing feature was the ability to go multiple days without accumulating unpleasant odors. That’s a major perk for me.

Imagine my surprise when I realized I could wear Merino wool shirts and boxer shorts for multiple days without exuding obnoxious odors or starting a mushroom farm in my crotch and armpits.

Wearing boxers multiple days without washing may seem like odd behavior. But on solo explorations of remote areas, my limited luggage capacity forces me to wear my clothes beyond the “laundry due date”, although my wife and children would claim the “disposal due date”. It’s not by choice, but laundromats are scarce in the wilderness. If you have any experience with synthetic undergarments, you know how quickly they become a putrefying biohazard if not washed daily. 

Thanks to Merino wool, I no longer have to incinerate my boxers at the end of a trip.

Durability on the move

The 80/20 merino/nylon blend is a winning combination for durability. The boxers held up well to the rigors of long-distance motorcycling, including multiple washes without shrinking. The inclusion of nylon in the fabric blend pays off. 

After a year and a half of intensive use, including multi-month adventure trips on three continents, the boxers have kept their form and still fit snugly as the fabric has not worn thin or lost elasticity. 

Design Features

The Teton Boxers feature a classic boxer brief design with a comfortable, fairly snug, no-bunching fit. The muted Klim branding ensures a clean look that complements any riding gear. A unique feature is the inclusion of a discreet “crush flap” opening, making those mid-ride sanitary pit stops a breeze.

The Verdict

The Klim Teton Merino Wool Boxers are a “must-have” addition to any motorcyclist’s wardrobe. Their comfort, breathability, moisture-wicking, odor resistance, and durability make them a compelling choice for long rides in both cold and hot weather. 

While the price point might be slightly higher than some synthetic base layers, the performance and natural properties of merino wool make it a worthwhile investment. Considering that these could replace 5 pairs of synthetic boxers on the road, their pricing makes them a steal.

These boxers made me rethink my multi-day packing strategy (fewer changes of underwear needed!). Just buy them, it’s a no-brainer. You will thank me later. 

Klim Teton Merino Shorts

Like five pairs of boxers in one, these are moisture wicking, odor-resistant, and don't chafe.

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Specs

• Klim-specific custom 80/20 blend of merino wool/nylon specifically designed for the rigors of motorcycling/snowmobiling while remaining 100% functional for casual use and retaining all of the benefits of merino wool.
• Knit from sub-17 micron merino fibers for unequaled comfort.
• 150 GSM merino wool (GSM = Gram per Square Meter, a unit of measurement of fabric weight. 150 GSM is the weight for ultra-lightweight merino wool).
• Extremely versatile/regulates your microclimate in both hot and cold climates (able to keep you warm and cool built into one garment).
• Antimicrobial / odor-resistant / multiple-day use without odor
• Maintains insulating value even while wet.
• Static resistant.
• Shrink resistant.
• Breathable.
• Stain resistant.
• Open body fit not too loose, not too tight.
• Muted branding.

Klim Teton Merino Wool Pants

The Klim Teton Merino Wool Pants are made of the same 80/20 merino wool/nylon blend as the boxers and possess the same qualities and design features. The pants’ performance in terms of breathability, insulation, reactive temperature regulation, moisture wicking, multi-day odor resistance, chafe-free comfort, and durability is identical to that of the boxers. 

I quickly came to appreciate these versatile undergarment pants, wearing them daily while riding in the mountains and cold weather. I always wore them over my boxers. At $80, they are great value and should be a fundamental part of your base layer kit. You can find cheaper synthetic leggings, but they won’t perform as well and will stink after a day, let alone multiple days. I won’t leave on a trip without my Klim Teton Merino Wool Pants. 

KLIM Teton Merino Wool Pant

$79.99

The only leggings you need for cold weather riding.

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06/07/2025 04:35 am GMT

Klim Teton Merino Wool LS Shirt

The Klim Teton Merino Wool Long-Sleeve Shirt is made of the same 80/20 merino wool/nylon blend and possesses the same qualities as the boxers and pants. There’s also a short-sleeved version of this long-sleeve shirt in the catalog. 

Fitting slightly loose, the shirt is just as soft and comfortable as the boxers and pants and performs identically in terms of breathability, insulation, reactive temperature regulation, moisture wicking, multi-day odor resistance, and durability. 

It has become my favorite base layer and is now an integral part of my riding kit and casual wardrobe. I like its neutral color, low-key look, and understated elegance, a far cry from the garish motocross jerseys in bright colors that require sunglasses to look at. I often wear it on my bicycle rides to a lunch meeting in the city, reassured it won’t show sweat stains thanks to its moisture-wicking capability. 

While writing this review, I was trying hard to come up with any drawbacks I could think of, as that’s what I’m expected to do as a gear reviewer. But since I’m very happy with the quality, fit, and performance of the Klim Teton merino wool base layers, there’s simply nothing negative to discuss.

At $80, the Klim Teton merino wool LS Shirt is priced competitively compared to other high-end brands. Like the boxers and pants in the Teton Merino wool line-up, the fit, quality, comfort, and thermal performance of the LS Shirt surpassed my expectations. 

Given how often I wear my Klim merino wool base and mid-layers, I find the Klim Teton product line great value and I fully recommend it to be a part of your technical base layers. You can find cheaper synthetic shirts, boxers, and pants, but they won’t perform as well and will stink after a day. I won’t leave on a trip without my Klim Teton Merino Wool Long-Sleeve Shirt, Pants, and Boxers. 

Boxers	Pants	Shirt
Klim Teton Merino Shorts	KLIM Teton Merino Wool Pants	KLIM Teton Merino Wool LS Shirt
Primary Rating: 5.0	Primary Rating: 5.0	Primary Rating: 5.0
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Boxers

Klim Teton Merino Shorts

Primary Rating:

5.0

Check Price on Revzilla

Pants

KLIM Teton Merino Wool Pants

Primary Rating:

5.0

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Check Price on Revzilla

Shirt

KLIM Teton Merino Wool LS Shirt

Primary Rating:

5.0

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Klim Teton 1/4 Zip Reviewed

Klim pitches its redesigned Teton Merino Wool ¼ Zip Shirt as the ultimate everyday multi-tool mid-layer that’ll keep you warm on and off the bike on cooler days. It’s a versatile shirt that feels soft and comfortable. It’s made of a thick lofty elastic fabric of high-quality merino wool reinforced with nylon for durability.

Like the Klim Teton merino wool base layers, the Teton ¼ Zip Shirt benefits from the same qualities being breathable, multi-day odor-resistant, and reactively regulating body temperature. 

You can wear it as a middle layer when riding in cooler weather, or just on its own for casual occasions. Its understated design, subdued features, and high-quality finish make it suitable for various settings. This shirt is a practical and comfortable choice for everyday wear.

In addition to keeping you warm and comfortable in inclement weather, this modular layering system of Teton base layers and Maverick Down Jacket offers great versatility. The various ways to combine the base and mid-layers allow you to adjust the level of insulation or warmth required to cope with the cold. 

I put this ¼ zip shirt to the test on multiple journeys on three continents to see if it lives up to its promise as a mid-layer under my motorcycle jacket and as a stand-alone casual jacket.

The ‘quality feeling’ of the Teton ¼ Zip Shirt’s fabric was the first thing that impressed me. Like its Teton base-layer siblings, it’s constructed from a soft merino wool/nylon blend, but the fabric is much thicker and loftier. This blend prioritizes the natural benefits of merino – breathability, odor resistance, and temperature regulation – while nylon adds durability to the material. Merrow stitching (AKA overlock) ensures chafe-free seams for comfort. 

This garment is the ultimate temperature regulator: during hot days, the shirt excelled at wicking away moisture, keeping me cool and dry. When temperatures dipped, the wool’s natural insulating properties provided warmth without feeling bulky. The ¼ zip closure proved to be a valuable feature, allowing for quick venting when needed and providing extra protection against wind chill when fully zipped.

One of the most appealing aspects of merino wool is its natural resistance to odor. Even after extended days in the saddle, the Teton ¼ Zip remained surprisingly fresh, similar to the Teton merino base layers. Keeping the stink at bay is a significant advantage, allowing you to pack lighter without risking being labeled a biohazard.

As far as durability, blending nylon into the merino wool helps this shirt keep its shape through daily wears and washes, and adds wind resistance to the insulation capacity.

The Teton ¼ Zip classic design with raglan sleeves allows for unrestricted movement on the bike. The slightly longer back is a nice touch, preventing bunching while riding.

The zip of the external chest pocket (large enough for a phone or wallet) is cleverly hidden in the seam of the front panel housing the main ¼ zip, while a subtle Klim logo next to it adds a touch of style. The ¼ zip features light-reflective striping for visibility in the dark.

The Verdict

The Klim Teton Merino Wool ¼ Zip Shirt is a versatile and valuable addition to my technical layering system. Its performance across various temperatures, wind resistance, impressive odor resistance, and comfortable design make it a top choice for layering. The ¼ zip closure adds functionality for on-the-go temperature management. While the price point ($130) might be slightly higher than some synthetic base layers, the natural properties of merino wool and the overall quality of the garment justify the investment.

Beyond living up to my high expectations of warmth and comfort, it impressed me with its durability and versatility. Just like the Maverick puffer jacket, the ¼ zip shirt has become a staple in my casual wardrobe.

Klim Teton Merino Wool 1/4 Zip Shirt

An excellent merino wool mid-layer on and off the bike.

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Specs

• Custom blend of merino wool/nylon for greater durability
• Lofty knit from premium merino wool fibers for exceptional comfort
• Low profile merrow stitching for comfort
• One hidden external chest pocket
• Extremely versatile – regulates body microclimate in hot and cold conditions
• Antimicrobial and multi-day odor-resistant
• Maintains insulating value even when wet
• Slightly loose fit
• Raglan sleeves
• Zipper garage
• Breathable
• Naturally stain resistant 
• Static resistant

Klim Maverick Down Jacket Reviewed

If you’ve ever found yourself questioning all your life choices while shivering on a motorcycle, teeth chattering so hard your twitching jaw muscles break the wind-blown frozen layer of snot on your face, then a warm puffer jacket might well be your next new best friend. 

Patched up and looking ragged and forlorn from years of abuse on my two-wheeled adventures, my old down jacket was beyond retirement age. Getting lighter after shedding most of its feathers through the stitch holes of the sewn-through baffles, I figured it was time to upgrade my thermal mid-layer. Enter Klim’s best-selling Maverick Down Jacket.

This jacket went so far beyond my expectations in comfort and versatility that I’m wearing it as a daily around-town jacket, as well as on the motorcycle.

Let’s get down to the nitty-gritty of this technical mid-layer.

The first thing you’ll notice is that the Klim Maverick Down Jacket is ultralight. It feels almost weightless, to the point where you wonder how such an ethereal puffer jacket can keep you warm. But after wearing it in brutally cold conditions, I can vouch for its effective thermal insulation. I never had a piece of clothing so incredibly light and warm as the Klim Maverick.

KLIM Maverick Down Jacket

$249.99

A down jacket for more than motorcycle riding. This weightless and highly packable gem is a daily around-town jacket as well.

Pros:

• Featherlight (pun intended)
• Packs down small
• Laughs at rain and wind

Cons:

• No hood

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The Secret to Light + Warm: Down Fill Power

How did Klim pull off the opposing design objectives of insulation and weightlessness? 

The secret sauce lies in its filling: The Maverick is packed to the gills with 800-fill-power down. Klim’s puffer jacket is fluffier than white cotton ball clouds in a blue sky on a mid-summer day… but way more practical.

If you’re not familiar with the fill power rating scale for down-filled apparel, then check out my article on layering in general.

The mid-layer, as any outdoors gear nerd will tell you, is crucial for staying warm when the going gets rough, temperature-wise. Goosedown still reigns supreme in the world of cold weather performance gear for extreme outdoor activities. It holds onto more air than any other material, meaning it keeps you warm and toasty without weighing you down.

The 800 fill-power goose down is super-efficient at keeping you warm without needing much of it. The down is 90/10 Responsible Down Standard (RDS) certified gray goose down. So you can feel good in a PC kind of way, knowing that the geese were treated humanely before generously donating their fluffy feathers to a charity-endorsed good cause, namely your comfort.

The 90/10 goose-down ratio indicates that the jacket filling consists of 90% down and 10% feather. This ratio is also known as the down-to-feather ratio or down-cluster ratio. The higher the down percentage, the better the warmth-to-weight ratio and the higher the quality and thermal insulation of the puffer jacket. 

Down is better at providing warmth and comfort than feathers, which can push through fabrics and are more suited to harder, more durable products. Another advantage of top-quality down with high fill power is that it lasts and keeps its loft a lot longer than cheaper, lower fill-power down.

With the Klim Maverick Down Jacket, you’re getting top-tier insulation without looking like the Michelin Man—a win for both warmth and style. 

Klim has another trick with this jacket: they engineered seamless down baffles, which not only sounds fancy but also means you won’t have down feathers poking out of stitch holes.

The baffle box construction method is a far superior design compared to the cheaper sewn-through construction which is notorious for shedding feathers and having cold spots at the seams. You can find out more about the ins and outs of puffer jacket construction in the relevant section in my article about layering in general.

Another advantage of the baffle box construction is that there are no visible sewing threads on the seams that risk getting caught on Velcro every time you put it on. 

The windproof, water-repellent outer shell is made of 20D nylon fabric. I found that the Maverick is impervious to wind, performing better than expected. I’ve often ridden in the city in freezing temperatures just wearing my puffer jacket and never felt the need to don a windproof outer shell. 

I’ve also worn my Maverick jacket while walking and cycling in light rain. The nylon fabric is treated with a DWR coating (Durable Water Repellent), and the raindrops just run off the jacket. So you won’t have to worry about getting soaked in a drizzle. Now, if it starts pouring cats and dogs, you might want to reach for a rain jacket, but this bad boy will hold its own in most conditions.

One of the practical features of the Maverick is that it packs very small, hardly taking up any space when storing it in your backpack or tank bag. The jacket folds up into one of the zippered hand pockets. So there’s no separate storage pouch that risks getting lost or that you don’t have with you when you need it. It’s the jacket version of a burrito—compact, satisfying, and always a good idea.

The Maverick is low-profile, easily fitting under your riding jacket, and the in-pocket bottom hem drawcord adjustment lets you get the perfect fit. One quick tug keeps the warmth in while the jacket is loose enough you don’t feel like a sausage.

The soft fabric zipper garage at the top of the main zipper is an easily overlooked small detail, but one that prevents the metal zipper slider from irritating the skin of your throat. My previous puffer jacket didn’t have a zipper garage, forcing me to leave the zipper open at the top to avoid the slider scratching my skin. This was especially annoying when cinching the outer jacket’s collar tight to prevent cold air ingress. 

Another minor detail that makes the Maverick more user-friendly is the spring-loaded pull tab keeping the locking pin firmly in position, preventing the zipper from sliding open inadvertently. Little things make a difference, right? 

The jacket also has two zip hand pockets, perfect for securely storing all the essentials—keys, phone, wallet, or… the jacket itself. Turned inside out, the right-hand side pocket doubles as the storage pouch for the jacket. 

Klim didn’t forget about safety, even though this is technically a mid-layer. But they know many owners also use it as a casual puffer jacket for everyday use. The jacket comes with 3M™ Scotchlite™ reflective material, which means you’ll shine bright like a diamond—or at least be visible to oncoming traffic.

The Klim Maverick Down Jacket is now a cornerstone piece of my casual spring/winter/fall wardrobe. It’s my go-to jacket on cold days and it gets worn a lot more than any of my other casual jackets. Whenever I can’t find it when I’m about to leave the house, it’s because my son is wearing it. I wear it while walking the dog, on my bicycle, and on my trips into the city. 

Drawbacks

The main drawback is that the Maverick doesn’t sport a hood. It would be nice to have a puffy hood (that folds away in the collar) to keep your noggin and ears warm when it’s cold and windy. Besides using the Maverick for layering under my riding jacket, I also use it as a daily casual jacket.

Another drawback is the lack of a lanyard sewn in the hand pocket that doubles as its storage pouch. When I take it off and stow it away in the turned-inside-out hand pocket, I have to hold it when I don’t bring a bag. It would be convenient to have a lanyard to hang it on my wrist or with a carabiner from my belt. Minor, but annoying.

Are you reading this, Klim designers in Rigby, ID?

Also, keep in mind that premium fill-power goose down commands a premium price. It’s used to keep puffer jackets ultralight, ultra-packable/compressible, and ultra-insulated. But the great part about high fill-power is it lasts long – so you won’t have to buy a new jacket in a year or two (like I did).

When you compare prices, make sure you compare apples to apples. The construction method (baffle box vs sewn-through), the quality (fill power and down-to-feather ratio), and the quantity (fill weight) of the down filling largely determine the cost. Also, goose down is more expensive than duck down and synthetic insulation like, for example, PrimaLoft or Thinsulate. As far as technical base layers from other brands, the Maverick is about the same price but also made for motorcycling.

Final Thoughts

The Klim Maverick Down Jacket is the kind of gear you’ll wonder how you ever lived without. It’s warm, comfy, super-light, and packed with smart features making it perfect for riding in cold weather. Plus, it’s so packable that it takes up almost no space in your tank bag or panniers, leaving plenty of room for the other essentials.

In short, the KLIM Maverick Down Jacket was a total win on all my ADV journeys on three continents. It teamed up perfectly with my Klim Badlands Pro A3 Jacket and Klim Traverse Jacket, and I was never once left out in the cold—literally or figuratively.

So, if you’re tired of shivering your way through cold rides and defrosting your shriveled nuts with your hand warmers, do yourself a favor and snag one of these Klim Maverick Down Jackets.

KLIM Maverick Down Jacket

$249.99

A down jacket for more than motorcycle riding. This weightless and highly packable gem is a daily around-town jacket as well.

Pros:

• Featherlight (pun intended)
• Packs down small
• Laughs at rain and wind

Cons:

• No hood

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We may earn commissions if you make a purchase. This keeps our site ad-free and never sponsored.

Specs

• 800-fill-power down.
• 90/10 Responsible Down Standard (RDS) certified gray goose down.
• Engineered seamless down baffles (reduces down loss, no stitching to snag on Velcro).
• Highly wind-resistant 20D nylon fabric.
• Packs into its own pocket.
• Durable Water Repellent (DWR) treatment on the fabric.
• Low profile cuff binding.
• 3M™ Scotchlite™ reflective material.
• 2 zip hand pockets.
• Low-profile elastic cuff binding traps heat.
• Low profile in-pocket bottom hem adjustment.
• Zipper garage.

Check out my article on layering in general where I break down materials and construction. Even after trying almost all the other base layers on the market: All the Klim base and mid layers in this article are the best (and best value) layers out there right now.

Boxers	Pants	Shirt
Klim Teton Merino Shorts	KLIM Teton Merino Wool Pants	KLIM Teton Merino Wool LS Shirt
Primary Rating: 5.0	Primary Rating: 5.0	Primary Rating: 5.0
Check Price on Revzilla	Check Price on Amazon	Check Price on Amazon
	Check Price on Revzilla	Check Price on Revzilla

Boxers

Klim Teton Merino Shorts

Primary Rating:

5.0

Check Price on Revzilla

Pants

KLIM Teton Merino Wool Pants

Primary Rating:

5.0

Check Price on Amazon

Check Price on Revzilla

Shirt

KLIM Teton Merino Wool LS Shirt

Primary Rating:

5.0

Check Price on Amazon

Check Price on Revzilla

The post Klim Maverick Jacket and Teton Base Layers Reviewed first appeared on It's Better On The Road.

I tested the Klim Badlands Pro A3, both jacket and pants, on a six-week adventure ride across Europe. Here’s what I found:

1. Its versatility for different weather conditions is superb; a rare trait even for an adventure suit. 
2. Its protection level is second to none in the adventure gear category. Unless you want to wear MotoGP leathers on the trails, it doesn’t get better than the Badlands Pro A3.
3. This suit includes it all: no need to layer abrasion protection over impact protection. That’s a HUGE convenience when out on a long adventure ride. 
4. The price is indeed steep; but a lot cheaper than a hospital visit (and I have the receipts to prove it).
5. This suit looks the part – but for that, pictures are a thousand words. 

The Best Adventure Jacket	The Best Adventure Pants
KLIM Badlands Pro A3 Adventure Motorcycle Jacket	KLIM Badlands Pro A3 Adventure Motorcycle Pants
The Klim Badlands Pro A3 has everything you need from an adventure suit: rugged protection, versatility to fit any conditions, comfort for long days, and endless customization. This is the best adventure jacket on the market.	Perfectly suited for any adventure ride, from long hours on the highway to hard enduro in the backwoods. Ride in comfort anywhere from the deserts of Morocco to the jungles of Vietnam.
5.0	5.0
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The Best Adventure Jacket

KLIM Badlands Pro A3 Adventure Motorcycle Jacket

The Klim Badlands Pro A3 has everything you need from an adventure suit: rugged protection, versatility to fit any conditions, comfort for long days, and endless customization. This is the best adventure jacket on the market.

5.0

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The Best Adventure Pants

KLIM Badlands Pro A3 Adventure Motorcycle Pants

Perfectly suited for any adventure ride, from long hours on the highway to hard enduro in the backwoods. Ride in comfort anywhere from the deserts of Morocco to the jungles of Vietnam.

5.0

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A New Standard in Adventure Riding Gear

When Klim launched the Badlands Pro A3 Jacket and Pants, they set a new benchmark for Adventure gear in several ways, from the first CE AAA-rated garment (same level as modern track leathers) featuring GORE-TEX waterproofing to a kidney belt system to keep the weight of the garment (and pockets contents) off the riders shoulders. 

Keep these in mind as you consider whether the Klim Badlands Pro A3 is for you. 

Key Elements:

• Material Composition: 3-Layer GORE-TEX Pro Shell, Vectran, CORDURA, SuperFabric, leather (more on these materials further in the article). Lining is Klimatek cooling mesh that’s moisture-wicking and breathable.
• Armor: D3O CE Level 2 that’s vented for airflow (Klim Aero Pro) at the elbows, shoulders, knees and hips. You also get a D3O CE Level 2 back pad (Viper Pro) AND tailbone pad. Chest pads are also included, made from thin sheets of Poron XRD impact protection foam, but they aren’t CE rated unfortunately. I replaced them with D3O CE Level 1 chest pads separately available from Klim.
• Ventilation: 18 vents in total, 12 on the jacket and 6 on the pants. You can go from all-mesh airflow to parka insulation and everything in between. 
• Storage: Jacket has 10 external and 4 internal pockets as well as a hydration bladder pocket in the back. Pants have just 2 large cargo pockets. More than I’ve ever seen on an adventure suit.
• Fit: Slack and roomy, just as you want from an adventure suit. However, you have several cinch cords and adjustment points to hold the sleeves and waist in place, and a kidney belt inside to support the weight of the jacket, pocket contents, and hydration bladder. 

What I Love:

• Similar protection as a race suit: This suit is rated to withstand 75 mph slides on asphalt (CE AAA) and has the top impact protection rating in the industry (CE Level 2) on almost all pieces of armor included. 
• Best waterproofing available on any garment: 3-layer GORE-TEX Pro. This isn’t just rare on motorcycle gear, it’s rare on any kind of outdoor gear. 
• Trail and adventure ready: With all-season versatility, tons of storage and customizable ventilation this jacket will suit you well whether you’re riding frigid trails in Vancouver, crossing the deserts of Morocco or slipping through the jungles of Thailand. 
• Exceptional comfort: The kidney belt and adjusters available all around 
• Guaranteed crash damage replacement: if you’re a hard rider, this will more than pay for itself, and makes the price tag easier to stomach.

What I Don’t Like:

• Weight: The kidney belt helps here, but the Badlands is still a heavy piece of kit compared to lighter armor-only suits you might wear in hot weather for purely off-road riding. 
• Hydration bladder not included: Maybe I’m nitpicking, but this seems like a strange omission on such a premium piece of gear. However, this does allow you to buy the exact model you like and insert it, e.g., the Klim Hydrapak available in 2L and 3L volume.
• Kidney belt retention system: As it’s elastic, the kidney belt automatically retracts upon releasing the Velcro closure into a storage compartment in the liner of the jacket. The triple retention tabs sewn onto both ends of the belt sometimes don’t catch onto the holding straps to prevent the belt from retracting completely into its sleeve, requiring to ‘fish’ it out again.
• Price tag: The Badlands Pro A3 is a premium suit with a premium price to match – that said, it might save you in hospital bills (or worse) down the line. Keep in mind that the price includes a crash replacement warranty, which is a major bonus.

Let’s get into my impressions and review of this suit over my six-week ride in Europe, starting with what I was looking for and then going through the finer points of this jacket and pants set. 

What I Was Looking For in Technical Riding Gear

After my recent crash, I was looking first and foremost for the best protection available in an adventure suit. Although I’m predominantly an off-road rider, riding stretches of pavement is unavoidable on my multi-week/month-long ADV journeys. So I wanted a suit that could flex between not only different climates but different riding conditions as well. 

I only considered gear with CE Level 2 protectors, since I’m not a huge fan of breaking bones. For the outer shell, I was looking for technical fabric that could withstand the rigors of trail riding – from thorns to sharp rocks – without ripping. Abrasion resistance was a top priority aimed at protecting my skin in the event of a spill on pavement. CE AAA abrasion resistance is the gold standard here. 

The final piece I was looking for in regards to protection is quality workmanship. This can be easy to overlook at the sight of a bargain price tag, but, in my experience, it is equally important to those safety ratings above. 

Sturdy seams, ideally triple-stitched, with high-tensile strength thread are a must. Even with strong material a jacket can be peeled open like a banana and rendered useless if the seams are too weak to hold up in a real-life crash. 

Klim hit all these marks with flying colors on the Badlands Pro A3 suit. Not only did it receive a CE AAA rating certified to Europe’s rigorous EN17092-2 standard, it’s the first-ever garment to do that while incorporating GORE-TEX waterproofing. 

Before I get into the next aspect I was looking for – versatility – a quick aside on safety ratings. You can skip this by clicking here. 

A Quick Overview of CE AAA and the CE EN17092 Safety Ratings

Let me walk you through the word salad of European safety ratings, in case you aren’t familiar. The EN17092 is the harmonized CE standard for motorcycle clothing. “CE” stands for “Conformité Européenne” (European Conformity in French), which governs the safety ratings for Personal Protective Equipment (PPE) for various industries and uses, from electronics to motorcycle gear. The CE certification system is known for being the most comprehensive and rigorous in testing and rating a wide range of products and materials.

Under EN17092, products are classified into five rating categories: AAA, AA, A, B, and C. The A-class rates gear based on a combination of abrasion and impact protection, while B and C-class ratings focus solely on abrasion resistance and impact protectors, respectively. 

The C-class for impact protection armor is divided into two levels: Level 1, where the maximum force transmitted upon impact cannot exceed 18 kN, and Level 2, limiting the force to no more than 9 kN transferred through the material. Learn more about what these ratings mean in our article on motorcycle body armor.  

The regulation further categorizes the body into three zones of risk for impact and abrasion, from the highest risk (Zone 1) to lower-risk areas (Zone 3). For Zone 1, think elbows, shoulders, hips, and knees. For For Zone 3, think chest and inner thighs. 

The CE AAA certification is the highest rating achievable for impact and abrasion protection, typically found in leather racing suits and advanced base layers like the BOWTEX Elite made from innovative materials. However, none of these AAA-certified garments include the highly sought-after GORE-TEX label. 

Versatility is King in Adventure Gear

Beyond protection, I wanted to find an adventure suit that was truly versatile. 

I’m thankful that the rise in popularity of adventure (ADV) and dual-sport (DS) motorcycling has brought new and old manufacturers into the market to innovate on gear. However, still relatively few brands build excellent adventure gear. The key word here is ‘excellent’.

All of their failures hinge on one missing element: versatility. 

Adventuring is inherently unpredictable. An adventure rider might go out for a day ride in the desert, only to find a flat tire keeps them there until late at night – when temperatures drop to frigid levels. 

Planning for adventure means planning for anything. And this is where purpose-built motorcycle gear always fails to do the job. Adventure gear must flex from sticky hot asphalt cruising to rainy conditions in the jungle, to wiping out on sands and rocks, to freezing rain in the mountains. It must be comfortable for long highway rides at high speeds and slow, grueling peg-standing workouts climbing rough single track trails. 

This may be part of the reason ADV gear is becoming so popular: one piece of gear can suffice for many conditions and types of riding. That’s saved money, space, and time. 

It’s for these reasons that creating a standout piece of adventure gear is the pinnacle of motorcycle gear design, in my opinion. Manufacturers that build a great piece of adventure gear must demonstrate their knowledge of rider needs, comforts, and protection in all situations. 

Klim: A Legacy of Innovation

Klim’s reputation for quality didn’t appear overnight. From their humble beginnings in Idaho to becoming a household name in the adventure riding community, Klim’s “No Compromise” approach to quality appealed to me from the time I bought their first pair of off-road pants in 2004. They’ve continued to push the envelope in technical garments for off-road and adventure motorcycle riders ever since. 

The Badlands Pro line, introduced in 2011, quickly became a favorite among serious riders. But Klim didn’t just sit back in the saddle and count their cash. 

The Badlands Pro A3 is a key example of Klim’s relentless innovation – even as the market leader, they continue to set higher standards. The collaboration with material suppliers to achieve the BLP A3’s CE AAA rating with GORE-TEX waterproofing is a testament to Klim’s commitment to keep building better gear.

So what is it about riding in the A3 suit that impressed me so much? 

Klim Badlands Pro A3: The New Standard in Adventure?

Klim doesn’t just stuff the Badlands Pro A3 full of buzzwords – they studied the needs of adventure riders to create a tougher, lighter and more durable garment for all types of rides and intensity levels. 

Klim’s latest flagship ADV combo has set a new benchmark for high-end adventure riding gear. The Badlands Pro A3 isn’t just about looking tough; it’s about being tough, with advanced design and cutting-edge fabric technology. 

Thanks to a mix of innovative materials and a smarter design, this suit is stronger, lighter, and more resistant to cuts and abrasions than any other ADV gear out there. It’s not just hype—this has been confirmed by Klim, my own testing, and the impressive CE AAA rating.

Breaking the CE AAA Barrier

So why hadn’t any GORE-TEX ADV gear hit the AAA mark before? Was the competition just not trying hard enough? Or was it that no fabric had yet managed to combine maximum protection with enough breathability to meet GORE-TEX’s stringent standards? 

The challenge wasn’t just about making a super protective suit; it was about creating one that also allowed enough breathability for the GORE-TEX membrane to do its job. Without proper breathability, the membrane can’t effectively let water vapor escape, which is a dealbreaker for GORE-TEX certification.

You see, a brand can’t just throw a GORE-TEX label on to anything – that garment must be tested by the GORE-TEX team to certify that it breathes enough air to be considered worthy of the tag. 

Klim took on this challenge head-on, working closely with their suppliers to develop state-of-the-art materials. They had previously partnered with the makers of CORDURA, SuperFabric, D3O, and 3M Scotchlite for the production of the CORDURA-chassis CE AA-certified Klim Badlands Pro, which remains available in Klim’s catalog as the more budget-friendly alternative to the top-of-the-line VECTRAN-chassis CE AAA-certified Badlands Pro A3. Both versions are identical in terms of layout and features, they only differ in the main outer shell fabric that makes up the chassis, namely CORDURA versus VECTRAN.

However, a heavy-duty CORDURA fabric that’s sufficiently thick to achieve AAA abrasion resistance certification wouldn’t breathe enough for the GORE-TEX membrane to function adequately, i.e., to let sweat evaporate. To remediate the lack of breathability, Klim resorted to using VECTRAN instead of CORDURA as the main outer shell material for the Badlands Pro A3. 

VECTRAN is an exceptionally strong fabric woven from a high-tensile-strength multifilament polyester yarn spun from a liquid-crystal polymer. The result? A suit that not only meets, but exceeds the toughest tests out there while still providing waterproofing and breathability worthy of the GORE-TEX name and the coveted CE AAA rating.

The Price of Excellence

Now, let’s talk about the elephant in the room—the price. 

Before I reveal it, you should know the price includes a replacement guarantee for gear damaged in a crash. Klim stands by that guarantee, and as far as I know no other brand offers this. 

The Badlands Pro A3 doesn’t come cheap, with an MSRP of $1,500 for the jacket and $970 for the pants. It’s a big investment, sure, but when you find yourself sliding across asphalt, the last thing you’ll be thinking about is the money you saved by skimping on gear. And when you’re done sliding, you’ll be glad you invested in the most protective ADV suit on the market. 

But the inclusion of the crash replacement warranty makes the hefty price tag a lot more acceptable. Although no one ever wants to send in a crash replacement warranty claim, knowing it’s part of the deal is reassuring for several reasons. Firstly, it indicates that Klim is confident that the VECTRAN chassis and SuperFabric armor will hold up in most crash scenarios without incurring damage. Otherwise, it wouldn’t be financially sustainable for Klim. Secondly, if the suit is to a large extent indestructible, it means it offers you maximum protection. Thirdly, if the suit does suffer damage, the replacement warranty will save you a lot of money.

So what did I put this suit through in order to make these claims? 

Putting the Badlands Pro A3 to the Test

To really put this suit through its paces, I packed it up and headed to Spain for a 6-week adventure across Europe’s most challenging terrains. Riding a Husqvarna Norden 901, I traversed the Sierra Nevada mountains, crossed the Algarve, and pushed north through the Pyrenees and the Alps. It was the perfect testing ground for the Badlands Pro A3, offering a mix of climates and conditions that truly challenged the gear.

And yes, my orthopedic surgeon gave me the green light, with a gentle reminder to go easy—a request my wife echoed, considering my last test ride in Thailand ended less than gracefully.

Collecting the bike from Lyndon Poskitt, a Dakar Rally legend and Klim and Husqvarna ambassador, I set off from Malaga through the Sierra Nevadas in Andalusia. I had already explored the Trans Euro Trail (TET) network in France and Spain last year, so I opted to take the Adventure Country Tracks (ACT) in Portugal and the Pyrenees this year. This network is similar to the Backcountry Discovery Routes (BDR) in the USA – both of which should be high on your bucket list. 

During my downtime on the trails, I researched more deeply into the specs of the suit I was wearing, from that VECTRAN outer shell to the SuperFabric abrasion zones and GORE-TEX layering. Here’s what I found. 

Specs VS Reality: Klim Badlands Pro A3

The Klim Badlands Pro A3 talks a big game – and I found it delivers even more. Let’s start with the shell. 

The shell and construction of the jacket and pants are about as detailed as it gets with motorcycle gear. 

The 3-Layer GORE-TEX Pro shell construction consists of the expanded PTFE membrane-backed VECTRAN, reinforced with ceramic SuperFabric abrasion zones on shoulders, elbows, forearms, and knees. You also get leather on the inner knees for better tank grip on the trails. 

VECTRAN fabric all around provides CE AAA-certified abrasion resistance (more on this below). All the details are finished perfectly, from 3M Scotchlite reflectors to YKK water-resistant zippers (double headed on the front zipper) and leather trim on the cuffs. 

So how does this word salad perform in the real world?  

Let’s start with the waterproofing: I rode in pouring rain for hours – had there been a leak, I would have felt it with the cold alpine winds blowing across my bike. Thankfully, the 3-Layer GORE-TEX Pro construction and YKK waterproof zippers did their job flawlessly. 

Klim is not selling you a marketing slogan here – the Badlands Pro A3 really does seal out the rain, without sealing in body heat and moisture. This is a remarkable achievement, given the jacket alone has 20 external zippers across vents and pockets, each with a hood at their termination point to keep even a dash of water from getting in. 

The GORE-TEX Pro 3-Layer Shell is a marvel of engineering – laminated together it moves like one layer, but allows the garment to seal out water while allowing moisture to wick away from the rider. There’s nothing as frustrating as the choice between getting wet from rain or wet from your own sticky sweat – most waterproof jackets only provide these two choices. The Badlands Pro A3 provides a third way – cool, dry, and comfortable in even the most wicked of storms. 

How about the materials on this suit – from SuperFabric to Vectran?

SuperFabric is a fascinating technology that applies perfectly for the needs of adventure riders hitting asphalt and trails. SuperFabric is a hi-tech hybrid material, taking advantage of the breathability and flexibility of a base layer loaded with a dense field of tiny round ceramic dots printed onto the base layer. 

These ceramic dots are astronomically harder than any fabric material – even leather. Imagine taking an industrial sander to a sample of leather and a piece of rock – which one will take more damage? 

SuperFabric gives you the wearability of a fabric with the abrasion resistance of a rock. It’s 10 to 15 times more abrasion resistant than aramid (Kevlar) and 5 times that of racing-grade leather.

The leather used on the inside of the knees on the Badlands Pro A3 is another testament to Klim’s knowledge of rider needs. Synthetic fabrics just don’t have the sticky gripping power (or heat resistance) of natural leather, so these patches allow the rider superior tank grip and bike control (without engine/exhaust pipe burns) when up on the pegs in tough off-road adventuring. 

Now to VECTRAN. The more affordable, original CE AA-certified Badlands Pro, Klim’s best-selling ADV suit which remains part of the catalog, utilizes CORDURA, a high-tenacity nylon fabric commonly used in various thicknesses in motorcycle textile gear construction. 

The VECTRAN fabric, used for the top-of-the-line CE AAA-certified Badlands Pro A3, improves on CORDURA significantly in that it is thinner, lighter, more flexible, and more abrasion/slash/tear resistant – all very important traits in adventure gear construction. 

What is VECTRAN? Compared to popular high-performance materials CORDURA and KEVLAR, it’s a technologically superior fabric made of polyester spun from a liquid-crystal polymer. So, how, and to what extent, does VECTRAN’s performance exceed that of CORDURA and KEVLAR? To do this, let’s look at the defining characteristics of each material, and see how they compare.

CORDURA is a high-performance, synthetic fiber-based fabric renowned for its durability and resistance to abrasions, slashes, tears, and scuffs. Made from nylon, it’s widely used in the production of outdoors and performance apparel and gear, like luggage, backpacks, motorcycle apparel, military clothing, etc.

KEVLAR started being applied for motorcycling apparel in the early 1990s. KEVLAR is the trademarked name for an aramid fiber made by DuPont. Aramid is the general name for an aromatic polyamide fiber with an extremely high tensile strength and a high strength-to-weight ratio – making it a popular choice for stopping punctures. Think bulletproof vests.

VECTRAN has the same tensile strength as aramid (Kevlar) but it is 3x more abrasion resistant. It combines cut/puncture resistance with abrasion resistance. It’s also more resistant to moisture and acidic and alkaline compounds than Cordura – meaning more durable despite the elements.

Klim backs up their material design with a crash damage replacement guarantee. Damage the Badlands Pro A3 in a crash and they will replace it free of charge. They clearly believe in its durability, or that guarantee would cost them too much to back it. 

Armor in the Klim Badlands Pro A3

When it comes to adventure riding, protection is paramount. The Klim Badlands Pro A3 takes this seriously with its top-notch armor system, designed to keep you safe without sacrificing comfort or mobility. Let’s dive into what makes this suit’s armor so impressive.

The Badlands Pro A3 is equipped with KLIM AERO PRO D3O CE Level 2 armor, offering high-level protection across various points of the body. This isn’t your run-of-the-mill foam padding; it’s a polymer suspended in liquid lubricant that turns hammer strikes into nudges. 

Jacket Armor Highlights:

• Shoulder Armor: KLIM AERO PRO D3O CE Level 2 vented 
• Elbow Armor: KLIM AERO PRO D3O CE Level 2 vented 
• Back Protection: D3O Viper Pro CE Level 2 back pad, vented
• Chest Pads: Comes standard with perforated XRD Impact Protection Foam, but can be upgraded to D3O CE Level 1 split chest pads for even better protection.
• Additional Features: Includes a kidney belt with easy access ports for adjustments and stowing.

Pants Armor Highlights:

• Hip Armor: KLIM AERO PRO D3O CE Level 2 vented 
• Knee Armor: KLIM AERO PRO D3O CE Level 2 vented and adjustable
• Tailbone / Coccyx Protection: KLIM AERO PRO D3O CE Level 2 armor

Why D3O Armor Beats Foam Every Time

D3O is not your typical foam padding; it’s a non-Newtonian material, meaning it’s soft and flexible during regular use but hardens upon impact to absorb and dissipate energy. This technology drastically reduces the force transmitted to your body, making it one of the best materials for impact protection.

The D3O Aero Pro armor has been specially developed for the Badlands Pro A3 to meet the breathability requirements set out by GORE-TEX. The open structure with large holes offers five times more ventilation than the widely-used standard options, without compromising protection. 

These new designs ensure that even with top-tier protection, you stay comfortable and cool. The armor is limb- and side-specific, optimizing coverage and stability during a fall. With internal mesh pockets and Velcro strips at the knees and elbows, you can easily adjust the positioning of the armor to fit your body perfectly.

Why the Armor Matters

In my own rigorous testing, I found the D3O armor not only met but exceeded my expectations. The Level 2 certification is the highest CE rating for impact protectors, and the D3O pads specifically developed for the Klim Badlands Pro A3 provide 44% more coverage than the standard options. Despite their size and thickness, the pads are surprisingly lightweight, thanks to extensive ventilation holes.

And yes, I’ve tested this armor in an unceremonious get-off. 

Let’s just say that my unscheduled test confirmed that the D3O armor does its job impeccably. The gear took the brunt of the impact, leaving the prosthetic received after my previous crash in Thailand intact. My fall was a replica of the one that landed me in a Thai hospital, but the impact absorbtion property of the protective D3O pads kept me out of the operation theater this time.  

As I had fallen on my recently reconstructed upper and lower limbs, I feared for a moment that I might have damaged my newly-fitted spare parts. But much to my surprise, I could move my limbs without feeling any pain. So, I got up and dusted myself off, lifted the bike up, and was on my way a few minutes later. 

That evening, I inspected the impact zones on the jacket and pant, and much to my surprise I couldn’t see any scratches, let alone damage. The only sign of contact was some dirt that got stuck between the tiny ceramic dots of the SuperFabric on the impact zones. After cleaning off the dirt with a wet brush, it was impossible to tell that my suit had been scraping over asphalt and dirt. Later, I even used a magnifying glass to inspect the SuperFabric’s ceramic dots, but there was no sign of visible scratches. 

Trust me, when you’re sliding along the pavement, the cost of the gear won’t enter your mind as it pales in comparison to the cost of surgery. Good gear pays for itself, and the Klim Badlands Pro A3 is no exception. 

Ventilation in the Klim Badlands Pro A3

When you’re out on the road, facing changing weather and temperatures, the ability to regulate your body heat is crucial. The Klim Badlands Pro A3’s ventilation system was one of the aspects that stood out during my cross-Europe test travels. It is the best-ventilated four-season suit I’ve ever worn.

The Badlands Pro A3 is equipped with an extensive array of vents designed to keep you cool when things heat up and seal out the cold when the temperature drops. Here’s what you get:

Jacket Ventilation Features:

• Wrist Vents: Two massive adjustable wrist vents with dual zippers allow you to control the airflow up into your sleeves precisely where you need it around your lower arms.
• Core Vents: Four vents on the core, two of which can double as pockets, provide significant airflow around your torso. 
• Bicep and Tricep Vents: Two intake vents on the biceps and two exhaust vents on the triceps ensure that air circulates effectively around your upper arms and arm pits.
• Back Exhaust Vents: Two vents on the back help to release hot air.
• Collar Tabs: A clever feature that allows you to keep the collar open, increasing airflow to the upper chest without the jacket flapping in the wind.

Pants Ventilation Features:

• Thigh Vents: Two intake vents on the thighs bring in cool air, while two exhaust vents release warm air.
• Lower Leg Vents: Additional side vents on the lower legs help to regulate temperature and provide further cooling. 

Is All This Ventilation Overkill?

You might think that all these vents are overkill, but they are essential for adapting to varying conditions. On a hot day, you might not notice just how much air is flowing through the suit, but as the temperature drops, the strategic placement of these vents becomes apparent. 

I noticed this clearly when riding up and down the mountain passes where temperatures were substantially cooler than in the valleys. The spacious fit of the Badlands Pro A3 ensures that air circulates freely around your torso and limbs, preventing any hot spots and keeping you comfortable.

Are these vents truly better than other adventure suits? 

I’ve ridden in all kinds of weather across five continents over the past fifty years, and I can confidently say that the Badlands Pro A3 offers the best ventilation I’ve ever experienced in an all-weather, four-season riding suit. The collar tabs, for instance, are a simple yet effective way to enhance ventilation around the neck and chest, a feature that many other suits lack.

Klim’s designers deserve high praise for nailing the ventilation system on the Badlands Pro A3. It’s not just about keeping comfortable; it’s about regulating your body temperature and hence maintaining alertness and poise on the bike, no matter the weather conditions. This suit lets you ride in comfort and safety, knowing that you’re equipped to handle whatever the road or trail throws your way.

Storage Galore: The Klim Badlands Pro A3

One of the standout features of the Klim Badlands Pro A3 is its impressive storage capacity. If you’re the type of rider who likes to have everything at your fingertips, this suit has you covered.

Jacket Storage Features:

• Hand Cargo Pockets: Two water-resistant, gusseted hand pockets with internal organizer compartments make it easy to keep smaller items sorted and accessible.
• Napoleon Pocket: A waterproof, externally accessible pocket ideal for storing important documents or electronics.
• Chest Pockets: Two vertical gusseted chest pockets, two vertical core pockets (which can also function as vents), a chest utility pocket, and an external MOLLE-compatible panel provide a multitude of options for stowing gear. I attached my Garmin inReach Mini2 Satellite Communicator/Personal Locator Beacon to the MOLLE utility chest panel.
• Internal Pockets: Inside the jacket, you’ll find two lower zippered stash pockets and a vertical chest stash pocket, perfect for valuablesa and documents.
• Specialized Pockets: The forearm has an emergency ID stat card pocket, and there’s a concealed document pocket behind the back pad, useful to hide passport and bike registration. A large dual-access gusseted back pocket can hold bulkier items like a midlayer or gloves.
• Hydration Compatibility: An internal compartment for a hydration bladder, with routing options for the hose, keeps you hydrated on long rides.

Pants Storage Features:

• Cargo Pockets: Two large thigh cargo pockets with billowed design for extra capacity.
• MOLLE Panel: An external MOLLE-compatible thigh utility panel offers additional attachment options.

With a total of 16 pockets, the Klim Badlands Pro A3 has the storage capacity of a large daypack, allowing you to carry everything you want easy access to. Stuffed with a bunch of energy bars and snacks, phone, maps, ear plugs, sun glasses, lip chapstick, SPF cream, EDC multitool, sun hat, woollen beanie, pair of (rain) gloves, toilet tissue, wet wipes, and a Garmin inReach Mini 2 satellite communicator, my pockets still had plenty of storage capacity left. However, with so many pockets, it’s easy to lose track of where you’ve put things. It’s worth developing a system to keep everything organized.

Fit & Comfort: Built for All-Day Riding

Klim is renowned for its generous fit, designed to maximize comfort and versatility, especially crucial in ADV gear where mobility and adaptability are key.

Jacket Fit & Comfort Features:

• Mobility Enhancements: Action-back gusseted shoulders and articulated seamless underarm gussets ensure freedom of movement.
• Comfort Liners: The jacket features a KLIMATEK cooling mesh full-sleeve liner and a moisture-wicking, breathable, antimicrobial mesh torso liner. The collar is lined with soft material for added comfort, and an adjustable cinch collar helps seal out the elements.
• Adjustability: Quick-adjust bicep and forearm straps, an adjustable bottom hem, and Velcro + zipper cuffs allow for a customized fit. The jacket-pant zip connection adds stability and protection as it prevents the jacket from riding up your back and exposing your skin when sliding across the pavement during a fall. This zippered connection helps to keep cold air out in combination with the integrated, removable kidney belt, which also provides lower back support.
• Layering Capability: The spacious fit allows for easy layering, ensuring you stay warm in colder conditions without feeling constricted. 

Pants Fit & Comfort Features:

• Mobility & Comfort: An articulated seamless crotch gusset and KLIMATEK cooling mesh in the armor pad pockets and behind the knees enhance comfort and mobility. The moisture-wicking, breathable, antimicrobial mesh liner helps regulate temperature.
• Adjustability: Velcro adjustable waist straps, quick-adjust knee straps, and a zipper + snap adjustable bottom hem allow for a precise fit. The pants are designed to fit over off-road boots, making them versatile for different riding styles.
• Weather Protection: A waterproof front zipper gusset adds an extra layer of protection against the elements.

The roomy fit of the Klim Badlands Pro A3 isn’t just for comfort—it’s a practical design choice that enhances ventilation and allows for effective layering. The extra space between the suit and your body helps air circulate, keeping you cooler in warm conditions and allowing space for thermal layers in the cold. For inclement weather, the Klim Merino Wool Mid-Layer and Maverick Down Jacket are the perfect accompaniment for the Badlands Pro A3.

Color & Sizing Options

When it comes to adventure riding gear, fit is part of functionality. The Klim Badlands Pro A3 doesn’t disappoint, offering a broad range of sizes and colors to suit various preferences and body types.

Sizing Options:

• Jackets: Available in sizes SM, MD, LG, XL, 2X, and 3X, the jackets are designed to accommodate a wide range of body types.
• Pants: The pants offer even more flexibility with regular sizes (30 to 42), short options (30 to 40), and tall sizes (32 to 38).

Color Options:

• Stealth Black: For those who prefer a sleek, understated look.
• Monument Gray – Petrol: A versatile, neutral option with a bit of flair.
• Petrol – Potter’s Clay: A distinctive color that stands out while still looking rugged and refined.

To help you find the perfect fit, Klim’s website provides a comprehensive sizing chart that’s proven accurate for me. For reference, I’m 6’3″ (190 cm) tall and, depending on the (festive) season, my weight fluctuates between 200 and 210 pounds (90 and 95 kg). The XL-Regular jacket and 36-Tall pants fit me perfectly. The sizing chart was spot-on for me, ensuring that the gear not only fits well but also allows for the full range of motion and comfort needed for long rides. 

Final Thoughts on the Klim Badlands Pro A3

Wearing this suit on the trails and the road makes me feel invincible – maybe that’s why I had an off! Everything from the D3O armor to the SuperFabric to the zippers and general construction of this suit inspires confidence all around. 

The best part about this suit is it melts away when I’m “in the zone” on the bike. The irony about a well-designed piece of gear is that the rider forgets it’s even there. No points to snag or constrain me as I’m cruising in the saddle or up on the pegs climbing a hill. Klim nailed it, not only in comfort and protection, but in flexibility, materials, and construction of these garments. 

And if it doesn’t fit you right off the rack, the adjustability in velcro straps, zippers, cinch cords, and kidney belt mean you’ll likely find a perfect fit for you and your riding style as long as the overall fit is generally correct. 

If you love what you’ve seen with the Klim Badlands Pro A3 but hesitate at the cost, consider how much your safety and comfort are worth to you, even for occasional rides. If you’re going to spend several thousand dollars every so often to fly and ride in some beautiful rugged terrain, an investment of a small fraction of that in a great suit that will last for many years, even decades, is a fair price to pay. The Klim Badlands Pro A3 is built to last and offers a level of protection and comfort that entirely justifies its price tag. 

And should you have a crash, the savings on hospital bills will surely more than make up for the cost of this suit. 

This is the most versatile, durable, weather-proof, feature-rich, protective, ventilated dual-sport/adventure suit on the market today. It pushes the boundaries in every way. Pick it up at the links below. 

The Best Adventure Jacket	The Best Adventure Pants
KLIM Badlands Pro A3 Adventure Motorcycle Jacket	KLIM Badlands Pro A3 Adventure Motorcycle Pants
The Klim Badlands Pro A3 has everything you need from an adventure suit: rugged protection, versatility to fit any conditions, comfort for long days, and endless customization. This is the best adventure jacket on the market.	Perfectly suited for any adventure ride, from long hours on the highway to hard enduro in the backwoods. Ride in comfort anywhere from the deserts of Morocco to the jungles of Vietnam.
5.0	5.0
Check Price on Revzilla	Check Price on Revzilla
Check Price on Amazon	Check Price on Amazon

The Best Adventure Jacket

KLIM Badlands Pro A3 Adventure Motorcycle Jacket

The Klim Badlands Pro A3 has everything you need from an adventure suit: rugged protection, versatility to fit any conditions, comfort for long days, and endless customization. This is the best adventure jacket on the market.

5.0

Check Price on Revzilla

Check Price on Amazon

The Best Adventure Pants

KLIM Badlands Pro A3 Adventure Motorcycle Pants

Perfectly suited for any adventure ride, from long hours on the highway to hard enduro in the backwoods. Ride in comfort anywhere from the deserts of Morocco to the jungles of Vietnam.

5.0

Check Price on Revzilla

Check Price on Amazon

Still not sure the Klim Badlands Pro A3 is for you? Check out the runner-ups for best adventure jackets and pants.

Here’s a list of all the other gear I wore on my 6-week journey across Europe on the Adventure Country Tracks (ACT), pictured throughout this article.

• Helmet: Nexx X.WRL Atika Helmet (until the next X.WRL model comes out, check out the Nexx X.WED3 ADV helmet)
• Boots: Gaerne SG-12 Boots
• Backpack: Klim Arsenal 30 Backpack
• Gloves
  • Klim Adventure GTX Short Gloves (Staff Pick at Revzilla)
  • Klim Badlands Aero Pro Gloves
• Mid Layers
  • Klim Teton Merino Wool 1/4 Zip Shirt
  • Klim Mojave Jersey
  • Klim Maverick Down Jacket
• Base Layers
  • Klim Tactical Short
  • Klim Aggressor Cool -1.0 Briefs
  • Klim Aggressor Cool -1.0 Long Sleeve Shirt
  • Klim Teton Merino Wool LS Shirt
  • Klim Aggressor Cool -1.0 Knee Brace Socks
  • Klim Vented Sock

For a review of several base layers worn on this trip, check out my Klim Base Layers overview.

The post Klim Badlands Pro A3 Review: The Ultimate Adventure Gear first appeared on It's Better On The Road.

After Evan and I crossed paths in Chiang Mai, we decided to team up to deliver more in-depth gear reviews to the motorcycling community combining Evan’s knowledge of website building and my experience with riding and gear.

Here’s a little about me:

After pursuing a zigzagging career leading nowhere across five continents, I was forced to face up to the undeniable truth that my stints working in the corporate rat race, Foreign Affairs, academia, and running my own companies, were merely ludicrous self-delusional attempts trying to hide that I was only cut out for one thing: riding motorcycles! 

Afflicted with two-wheeled wanderlust born from an innate curiosity for what’s beyond the horizon, I pursued an international career spanning Europe, Africa, Australia, North America, and Asia. An unconditional requirement for accepting overseas assignments was the opportunities for motorcycling the location offered, leading me to turn down a promising career opportunity on Wall Street, much to my father’s disappointment.

I greatly enjoy exploring faraway places on a motorcycle. Nothing lifts my spirit more than riding gnarly trails into a remote mountain range or desolate desert and rolling out my sleeping bag next to my bike for a blissful night under the stars. If not out riding, I enjoy reading, mountain biking, tinkering with motorcycles, and writing for motorcycle magazines including ADVMoto Magazine and GearJunkie. 

Although a veteran of intercontinental bike trips, I keep adding far-flung destinations to my bucket list. I consider myself fortunate to share my love for motorcycling with my wife and adult kids, who all ride too. To facilitate living our passion, the family keeps a motorcycle fleet at our base camps in Belgium, Thailand, Portugal, and California. 

I’m excited to share more of my explorations and what I learn along the way with you!

The post Introducing Jan Marc Staelens – Senior Editor first appeared on It's Better On The Road.